An intelligent sorting system and its working method

Abstract

The present invention provides an intelligent sorting system and its working method. The intelligent sorting system includes a conveying mechanism, a detection mechanism, a storage and sorting mechanism, a palletizing mechanism, and a control mechanism. The conveying mechanism is used for conveying plates, the detection mechanism is used for detecting the plates on the conveying mechanism, the storage and sorting mechanism is used for sorting and storing plates, the palletizing mechanism is used for palletizing and packaging the plates on the palletizing conveyor line, and the control mechanism is connected to the conveying mechanism, the detection mechanism, the storage and sorting mechanism, and the palletizing mechanism, and controls the operation of each mechanism. The intelligent sorting system provided by the present invention realizes the automation of plate sorting through the cooperation of each mechanism, realizes the storage and sorting output of plates in different hoppers. The rotary hopper has a large storage capacity of plates and a small floor area, improving the space utilization rate. It not only improves the efficiency of plate sorting but also reduces the cost of plate sorting.

Description

Technical Field

[0001] The present invention relates to the technical field of sheet sorting, and particularly to an intelligent sorting system and its working method. Background Art

[0002] In the processing of panel furniture, in order to improve the utilization rate of raw materials, different-sized sheets from different orders are usually cut on the same piece of raw material, and then uniformly placed on a conveyor line and transported to the next processing production line. This results in the sheets of the same order being in different batches, and the sheet loading process is disorderly. When subsequent production processing and packaging of the sheets in the order are carried out, the sheets of the same order still need to be sorted out from different batches. Manual sorting not only has a large labor intensity, long time consumption, and low efficiency, but also causes the overall progress of subsequent production processing and packaging processes to be slow, resulting in an increase in processing costs.

[0003] In order to improve the sorting efficiency of sheets, sorting robots are currently widely used to replace manual sorting. However, the existing robot sorting systems still have the following problems: they require a large storage space to store sheets, occupy a large floor area; they cannot achieve synchronous feeding and discharging, and have a low sorting efficiency; they require multiple sorting robots to work simultaneously, resulting in high costs. Summary of the Invention

[0004] To solve the above problems, the present invention provides an intelligent sorting system and a working method.

[0005] To achieve the above technical effects, the technical solution of the present invention is as follows:

[0006] An intelligent sorting system includes a conveying mechanism, a detection mechanism, a storage and sorting mechanism, a palletizing mechanism, and a control mechanism. A first barcode scanning mechanism and a second barcode scanning mechanism are respectively provided at the input ends of the detection mechanism and the storage and sorting mechanism.

[0007] The conveying mechanism is used to convey sheets, and includes a conveying support and a loading area, a detection area, a storage and sorting area, and a palletizing area sequentially arranged on the conveying support; the loading area is provided with a loading conveyor line, the detection area is provided with a detection conveyor line and a sheet return line, the storage and sorting area is provided with a feeding conveyor line, a discharging conveyor line, and a feeding push plate assembly, and the feeding push plate assembly is used to push the sheets on the feeding conveyor line into the storage and sorting mechanism; the palletizing area is provided with a palletizing conveyor line; the loading conveyor line, the detection conveyor line, and the feeding conveyor line are sequentially connected, the discharging conveyor line is connected to the palletizing conveyor line, and the sheet return line is correspondingly arranged on one side of the detection conveyor line and is connected to the detection conveyor line.

[0008] The detection mechanism is correspondingly arranged above the detection area of the conveying mechanism and is used to detect the plates on the conveying mechanism. The detection mechanism includes a CCD camera and a structured light optical system. When the plate to be detected is conveyed on the conveying mechanism, the CCD camera is used to capture the surface image of the plate to be measured, and the structured light optical system is used to generate a number of structured lights symmetrically arranged on both sides of the CCD camera at different angular postures along the movement direction of the plate;

[0009] The storage and sorting mechanism is correspondingly arranged on one side of the storage and sorting area of the conveying mechanism and is used to sort and store plates. The storage and sorting mechanism includes a sorting rack, a driving component, a transmission component, an annular guide rail, a number of hoppers, a discharge push plate component, a feed inlet and a discharge outlet arranged on the sorting rack. The transmission component is fixedly connected to the hopper. The driving component drives the hopper to rotate vertically along the annular guide rail through the transmission component to drive each hopper to the feed inlet or the discharge outlet. The feed inlet and the discharge outlet are respectively correspondingly arranged with the feed conveying line and the discharge conveying line. The discharge push plate component is correspondingly arranged with the discharge outlet and is used to push the plates in the hopper to the discharge conveying line;

[0010] The palletizing mechanism is correspondingly arranged at the output end of the palletizing area and is used to palletize and package the plates on the palletizing conveying line. It includes a palletizing rack and a suction cup component arranged on the palletizing rack. The suction cup component is connected to the palletizing rack through a three-dimensional motion component;

[0011] The control mechanism is connected to the conveying mechanism, the detection mechanism, the storage and sorting mechanism and the palletizing mechanism and controls the operation of each mechanism.

[0012] Preferably, both ends of the plate return line are connected to the detection conveying line, and a flap mechanism is arranged between the plate return line and the detection conveying line.

[0013] Preferably, there are two or more feed push plate components to simultaneously push the plates at different positions on the feed conveying line to different positions in the hopper, improving the working efficiency of the system; there are two or more discharge push plate components to simultaneously push the plates at different positions in the hopper to the discharge conveying line, improving the working efficiency of the system.

[0014] Preferably, a number of material blocking components are arranged on the feed conveying line. The material blocking components include a material blocking cylinder and a material blocking baffle connected to the material blocking cylinder. The material blocking cylinder drives the material blocking baffle to lift and lower to limit the plates on the feed conveying line so that they are pushed into the hopper at different workstations.

[0015] Preferably, a plurality of wear-resistant components are provided on both the feeding conveyor line and the discharging conveyor line. The wear-resistant components on the feeding conveyor line are arranged corresponding to the feeding port, and the wear-resistant components on the discharging conveyor line are arranged corresponding to the discharging port. The wear-resistant component includes a lifting cylinder and a wear-resistant plate connected to the lifting cylinder. The lifting cylinder drives the wear-resistant plate to lift and lower, so that the plate can be conveyed on the wear-resistant plate, thereby reducing the frictional wear of the plate on the feeding conveyor line and the discharging conveyor line.

[0016] Preferably, according to the different positions of the hopper, the control mechanism can control the hopper to rotate clockwise or counterclockwise, so that the hopper can reach the feeding port or the discharging port along the shortest path for the storage or sorting and output of the plates, improving the working efficiency of the system.

[0017] Preferably, the hopper is divided into a plurality of sub-hopper layers. The sub-hopper layers can store plates at different positions according to different plate specifications, and each sub-hopper layer can store a plurality of plates at the same time, further increasing the storage capacity of the plates in the system.

[0018] Preferably, a plurality of the structured light strips are evenly arranged on both sides of the CCD camera, and the layout angle range is 0 - 180°. The structured light optical system includes a plurality of structured light sources symmetrically arranged on both sides of the CCD camera along the movement direction of the plate. The structured light source includes a laser, a Powell prism, and a mask. The mask is installed below the Powell prism, and the mask is a rectangular mask or a feature mask.

[0019] In addition, the present invention provides a working method for an intelligent sorting system, including the following steps:

[0020] S1. Loading: The plates with information such as model, size, and order number are sequentially placed in the conveying area of the loading mechanism. The first barcode scanning mechanism scans the plate information and transmits it to the control mechanism.

[0021] S2. Detection: The conveying mechanism conveys the plate to the detection area, and the detection mechanism measures whether the size of the plate and the positions and sizes of the holes and grooves on the plate meet the requirements, and conveys the plates that meet the requirements to the storage and sorting mechanism, and rejects the plates that do not meet the requirements.

[0022] S3. Storage and sorting: The second barcode scanning mechanism scans the plate information and transmits it to the control mechanism. The control mechanism controls the plates that meet the requirements to be conveyed to the corresponding hoppers of the storage and sorting mechanism. When all the plates of the same order are stored completely, the control mechanism controls the different plates of the same order to be continuously output to the palletizing area.

[0023] S4. Palletizing: The plates conveyed to the palletizing area are stacked as required to complete the sorting of the plates with the same order number.

[0024] Preferably, in step S2, for a plate with holes and grooves on both sides, after one measurement, it returns through the plate return line, is flipped by the turning mechanism, and then enters the detection mechanism for secondary measurement; for plates that meet the requirements, they are conveyed by the feeding conveyor line to the corresponding hoppers of the storage and sorting mechanism; for plates that do not meet the requirements, after passing through the plate return line, they do not enter the turning mechanism and directly flow back to the recycling area.

[0025] Preferably, in step S2, the detection process includes the following steps:

[0026] S21. Install a CCD camera and a structured light optical system, and the structured light optical system is symmetrically distributed on both sides of the CCD camera;

[0027] S22. Generate structured light, and the process is as follows: Turn on the laser in the structured light optical system, and the laser beam generated by the laser passes through a Powell prism and a mask in sequence to generate a parallel strip-shaped laser line with a specific size range and clear edges;

[0028] S23. Turn on the CCD camera to obtain the four-dimensional coordinates of any point on the surface of the plate, and the process is as follows: Make the plate to be measured move forward at a certain speed on the conveying platform, and the CCD camera continuously scans and takes pictures to obtain the two-dimensional image of the surface of the plate, and transmits it to the control mechanism. After receiving the image, the control mechanism performs information processing to obtain the three-dimensional coordinates of any point on the surface of the plate, and by superimposing the gray values of each point in the image, the four-dimensional coordinates of any point on the surface of the plate are obtained.

[0029] Preferably, in step S22, the generated structured light is a parallel strip-shaped laser line with a width of 5-20 mm, and the contours of its upper and lower edges are clear and the straightness is less than 0.1 mm, which is specifically selected according to the measurement accuracy requirements.

[0030] Preferably, in step S23, the process of obtaining the three-dimensional coordinates of any point on the surface of the plate is as follows: Combine the width, incident angle of the structured light and the coordinates projected on the plane in theory with the projected width and projected coordinates of the structured light in the two-dimensional image, and calculate the three-dimensional coordinates of the projected edge contour based on the calibration data of the CCD camera; By symmetrically arranging a number of structured lights on both sides of the CCD camera at different angular postures, the three-dimensional coordinates of several lines on the surface of the plate can be obtained, and the three-dimensional coordinates (X, Y, Z) of any point on the surface of the plate to be measured can be obtained by mathematical fitting. The four-dimensional coordinates are (X, Y, Z, P), where P is the gray value, and the gray value is obtained from the brightness of the structured light in the two-dimensional image.

[0031] Preferably, in step S3, the storage and sorting process is as follows:

[0032] The control mechanism plans the hoppers corresponding to each sheet and the storage positions in the hoppers according to the sheet information, and controls the driving assembly to work. The driving assembly drives the hopper to rotate vertically along the annular guide rail through the transmission assembly, so that the corresponding hopper is driven to the feeding port along the planned path, and the feeding push plate assembly pushes the sheet into the corresponding position of the hopper; when the control mechanism recognizes that all the sheets of the same order have been stored, it will control the corresponding hopper to rotate to the discharging port, and the discharging push plate assembly continuously outputs different sheets of the same order to the discharging conveyor line and transports them to the palletizing area for palletizing, completing the sorting of the sheets with the same order number.

[0033] Preferably, during the storage and sorting process, according to the different sizes of each sheet, the stop air cylinder in the stop component controls the stop baffle to rise or fall to limit each sheet at different workstations and enter different positions in the hopper.

[0034] The beneficial effects of the present invention are as follows:

[0035] (1) The present invention provides an intelligent sorting system, including a conveying mechanism, a detection mechanism, a storage and sorting mechanism, a palletizing mechanism and a control mechanism. Each mechanism cooperates with each other to realize the automation of sheet sorting, realizes the storage and sorting output of sheets in different hoppers. The rotary hopper has a large storage capacity for sheets and a small floor area, improving the space utilization rate. It not only improves the efficiency of sheet sorting but also reduces the cost of sheet sorting.

[0036] (2) Each hopper of the present invention is divided into several sub-hopper layers, which increases the storage capacity of the hopper and makes full use of the storage space.

[0037] (3) A number of stop components are provided on the feeding conveyor line of the present invention to limit the sheets on the conveyor line, so that sheets of different sizes can be pushed into the hopper at different workstations, making reasonable use of the storage space of the hopper.

[0038] (4) A number of wear-resistant components are provided on both the feeding conveyor line and the discharging conveyor line of the present invention, which enables the sheets to be transported on the wear-resistant plates, thereby reducing the frictional wear of the sheets on the conveyor line.

[0039] (5) The detection mechanism of the present invention can eliminate the light source blind area during photographing by symmetrically arranging a number of structured lights with multi-angle postures on both sides of the CCD camera, and irradiate with light sources at different angles synchronously, obtaining a clear-edge sheet surface image to achieve precise measurement of the sheet.

[0040] (6) Based on the clear edge contours and brightness of multiple strip structured lights, the detection mechanism of the present invention can calculate the four-dimensional coordinates of any point on the surface of the sheet. The measurement accuracy is high. Compared with the existing line structured light measurement method, the efficiency is increased by 2-5 times, and the accuracy can reach the pixel level. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 is a schematic structural diagram of the intelligent sorting system of the present invention;

[0042] Figure 2 is Figure 1 an enlarged schematic diagram of the circled part in

[0043] Figure 3 is a schematic diagram of the working state of the present invention;

[0044] Figure 4 is a schematic structural diagram of the storage and sorting mechanism and the storage and sorting area of the conveying mechanism of the present invention;

[0045] Figure 5 is a schematic structural diagram of the hopper of the present invention;

[0046] Figure 6 is a schematic structural diagram of the storage and sorting area of the conveying mechanism of the present invention;

[0047] Figure 7 is a schematic principle diagram of the detection mechanism of the present invention;

[0048] Figure 8 is a layout diagram of the strip structured light of the present invention, where 8-a is a schematic diagram of the strip structured light distribution, and 8-b is a schematic diagram of the light band formed when the strip structured light is projected onto the surface of the conveying platform;

[0049] Figure 9 is a schematic principle diagram of the strip structured light eliminating the visual blind area of the present invention;

[0050] Figure 10 is a schematic principle diagram of the generation of the strip structured light of the present invention;

[0051] Figure 11 is a schematic principle diagram of the rectangular mask of the present invention;

[0052] Figure 12 is a schematic principle diagram of the strip feature mask of the present invention;

[0053] Figure 13 is a schematic diagram of obtaining the coordinates of the upper and lower edges of the strip structured light in the CCD camera when a strip structured light is incident on the surface of the conveying platform of the present invention;

[0054] Figure 14 is a schematic diagram of obtaining the coordinates of the upper and lower edges of the strip structured light in the CCD camera respectively when two strip structured lights are incident on the surface of the conveying platform of the present invention;

[0055] Figure 15 Schematic diagram of the X coordinates of the front and rear edges of the structured light strip when the sheet to be measured passes through the structured light strip;

[0056] Figure 16 The three-dimensional contour curve that can be obtained by continuously scanning multiple structured light strips through a CCD camera;

[0057] Figure 17 Schematic diagram of the projection principle of the image inside the edge of the structured light strip.

[0058] In the figure: 1 Conveyor mechanism, 11 Loading conveyor line, 12 Detection conveyor line, 13 Sheet return line, 14 Feeding conveyor line, 15 Discharging conveyor line, 16 Palletizing conveyor line, 17 Wear-resistant component, 171 Wear-resistant plate, 18 Material blocking component, 181 Material blocking baffle, 19 Feeding push plate component, 191 Feeding push plate, 2 Detection mechanism, 21 CCD camera, 22 Structured light optical system, 221 Laser, 222 Powell prism, 223 Mask, 2231 Rectangular mask, 2232 Rectangular light passing area, 2233 Feature band mask, 2234 Feature band light passing area, 2235 Feature pattern, 224 Light ray, 225 Structured light strip, 23 Conveyor platform, 3 Storage and sorting mechanism, 31 Discharge port, 32 Driving component, 33 Transmission component, 34 Discharging push plate component, 341 Discharging push plate, 35 Ring rail, 36 Sorting rack, 37 Hopper, 371 Hopper a, 372 Hopper b, 373 Sub-hopper layer, 38 Feeding port, 4 Palletizing mechanism, 41 Palletizing rack, 42 Suction cup component, 43 Three-dimensional motion component, 44 Palletizing storage area, 5 First barcode scanning mechanism, 6 Second barcode scanning mechanism, 7 Flap mechanism, 8 Robot, 9 Sheet. Detailed implementation manners

[0059] The following elaborates on the preferred embodiments of the present invention in conjunction with the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making the protection scope of the present invention more clearly defined.

[0060] See Figures 1 to 3 , an intelligent sorting system, including a conveyor mechanism 1, a detection mechanism 2, a storage and sorting mechanism 3, a palletizing mechanism 4 and a control mechanism (not shown in the figure), and a first barcode scanning mechanism 5 and a second barcode scanning mechanism 6 are respectively provided at the input ends of the detection mechanism 2 and the storage and sorting mechanism 3.

[0061] The conveying mechanism 1 is used to convey the sheet material 9, and it includes a conveying support and a loading area, a detection area, a storage and sorting area, and a stacking area that are sequentially arranged on the conveying support; the loading area is provided with a loading conveyor line 11, the detection area is provided with a detection conveyor line 12 and a sheet material return line 13, the storage and sorting area is provided with a feeding conveyor line 14, a discharging conveyor line 15 and a feeding push plate assembly 19, and the feeding push plate assembly 19 is used to push the sheet material 9 on the feeding conveyor line into the storage and sorting mechanism 3. The stacking area is provided with a stacking conveyor line 16; the loading conveyor line 11, the detection conveyor line 12 and the feeding conveyor line 14 are sequentially connected, the discharging conveyor line 15 and the stacking conveyor line 16 are connected, and the sheet material return line 13 is correspondingly arranged on one side of the detection conveyor line 12 and is connected to the detection conveyor line 12.

[0062] The detection mechanism 2 is correspondingly arranged above the detection area of the conveying mechanism 1 and is used to detect the sheet material 9 on the conveying mechanism 1.

[0063] The detection mechanism 2 can detect five surfaces of the sheet material 9 (synchronous scanning measurement of the front, left and right surfaces, and front and back surfaces), and can complete the measurement of the dimensions, hole positions, grooves, etc. of the five surfaces of the sheet material 9 at one time. For a small number of sheet materials 9 that require six-sided detection (such as having holes on the reverse side), for the detection of these sheet materials 9, both ends of the sheet material return line 13 can be connected to the detection conveyor line 12, and a flap mechanism 7 is provided between the sheet material return line 13 and the detection conveyor line 12. The flap mechanism 7 can turn the sheet material 9 twice and enter the detection mechanism 2 to detect the reverse side, which is suitable for six-sided detection of the sheet material 9.

[0064] The storage and sorting mechanism 3 is correspondingly arranged on one side of the storage and sorting area of the conveying mechanism 1 and is used to sort and store the sheet material 9.

[0065] The stacking mechanism 4 is correspondingly arranged at the output end of the stacking area and is used to stack and package the sheet material 9 on the stacking conveyor line 16. It includes a stacking machine frame 41 and a suction cup assembly 42 arranged on the stacking machine frame 41. The suction cup assembly 42 is connected to the stacking machine frame 41 through a three-dimensional motion assembly 43 and can move on the X, Y, and Z axes respectively through the three-dimensional motion assembly 43. The sheet material 9 is successively sucked from the stacking conveyor line 16 and placed in the stacking storage area 44 for stacking and packaging.

[0066] The control mechanism is connected to the conveying mechanism 1, the detection mechanism 2, the storage and sorting mechanism 3 and the stacking mechanism 4, and controls the operation of each mechanism.

[0067] Figure 3 This is a schematic diagram of the working state of the system. The feeding and stacking operations of the sheet material 9 can be carried out manually or by a robot 8.

[0068] See Figures 4 to 6, the storage and sorting mechanism 3 includes a sorting rack, a driving component 32, a transmission component 33, an annular guide rail 35, a plurality of hoppers 37, a discharge push plate component 34, a feed inlet 38 and a discharge outlet 31 arranged on the sorting rack. The transmission component 33 is fixedly connected to the hopper 37. The driving component 32 drives the hopper 37 to rotate vertically along the annular guide rail 35 through the transmission component 33, so as to drive each hopper 37 to the feed inlet 38 or the discharge outlet 31. The feed inlet 38 and the discharge outlet 31 are respectively arranged corresponding to the feed conveyor 14 and the discharge conveyor 15. The discharge push plate component 34 is arranged corresponding to the discharge outlet 38, and is used to push the board 9 in the hopper 37 to the discharge conveyor 15.

[0069] In addition, the control mechanism can control the hopper 37 to rotate clockwise or counterclockwise, so that the hopper 37 can reach the feed inlet 38 or the discharge outlet 31 along the shortest path for the storage or sorting and output of the board 9, thereby improving the working efficiency of the system. For example, Figure 4 in the middle, the hopper 37 is divided into two rows, the hopper a 371 and the hopper b 372 are arranged opposite to each other. When the board in the hopper a 371 needs to be output, the control mechanism controls each hopper 37 to rotate counterclockwise, so that the hopper a 371 rotates to the discharge outlet 31, and then the discharge push plate component 34 pushes the board in the hopper a 371 onto the discharge conveyor 15; when the board in the hopper b 372 needs to be output, the control mechanism controls each hopper to rotate clockwise so that the hopper b 372 rotates to the discharge outlet 31 and then outputs the board 9.

[0070] The hopper 37 can be divided into several sub-hopper layers 373. Each sub-hopper layer 373 can store boards at different positions according to different board specifications. Several boards can be stored in each sub-hopper layer 373 at the same time, further increasing the board storage capacity of the system.

[0071] The feed push plate component 19 includes a feed cylinder and a feed push plate 191 connected to the feed cylinder. When the feed conveyor 14 conveys the board 9 to the feed inlet 38, the feed cylinder controls the feed push plate 191 to push the board 9 into the sub-hopper layer 373 corresponding to the feed inlet 38. In addition, there are two or more feed push plate components 19 to simultaneously push the boards 9 at different positions on the feed conveyor 14 to different positions in the sub-hopper layer 373, improving the working efficiency of the system.

[0072] A number of material blocking components 18 are provided on the feeding conveyor line 14. The material blocking component 18 includes a material blocking cylinder and a material blocking baffle 181 connected to the material blocking cylinder. The material blocking cylinder drives the material blocking baffle 181 to lift and lower, so as to limit the position of the sheet 9 on the feeding conveyor line 14, and push it into the hopper 37 at different workstations. For example, when there are 3 sheets 9 of different sizes stored in the sub-hopper layer 373, there are 3 feeding push plate components 19 and 3 material blocking components 18 respectively. The material blocking cylinder controls the material blocking baffle 181 to rise to limit the positions of the 3 sheets respectively, and then the feeding cylinder controls the feeding push plate 191 to push the 3 sheets limited at different positions on the feeding conveyor line 14 to the corresponding positions in the sub-hopper layer 373. And so on for other situations.

[0073] The discharging push plate component 34 includes a discharging cylinder and a discharging push plate 341 connected to the discharging cylinder. The discharging cylinder controls the discharging push plate 341 to move back and forth to push the sheet 9 in the sub-hopper layer 373 onto the discharging conveyor line 15. And, the discharging push plate component 34 is also provided with two or more to realize pushing the sheets 9 at different positions in the sub-hopper layer 373 onto the discharging conveyor line 15 at the same time.

[0074] A number of wear-resistant components 17 are provided on both the feeding conveyor line 14 and the discharging conveyor line 15. The wear-resistant components 17 on the feeding conveyor line 14 are arranged corresponding to the feeding port 38, and the wear-resistant components 17 on the discharging conveyor line 15 are arranged corresponding to the discharging port 31; the wear-resistant component 17 includes a lifting cylinder and a wear-resistant plate 171 connected to the lifting cylinder. The lifting cylinder drives the wear-resistant plate 171 to lift and lower, so that the sheet 9 can be conveyed on the wear-resistant plate 171, thereby reducing the frictional wear of the sheet 9 on the feeding conveyor line 14 and the discharging conveyor line 15.

[0075] See Figure 7 , the detection mechanism 2 includes a CCD camera 21 and a structured light optical system 22. When the sheet 9 to be detected is conveyed on the conveying mechanism 1, the CCD camera 21 is used to capture the surface image of the sheet 9 to be detected, and the structured light optical system 22 is used to generate a number of structured lights 225 symmetrically arranged at different angular postures on both sides of the CCD camera 21 along the moving direction of the sheet 9; the image captured by the CCD camera 21 is transmitted to the control mechanism for information processing. Among them, the arrow direction in the figure is the moving direction of the sheet 9.

[0076] A number of the structured light belts 225 are evenly arranged on both sides of the CCD camera 21, and the arrangement angle range is 0 - 180°. The structured light belt 225 of the present application is a strip-shaped light beam with clear contours, which do not interfere with each other and cover the full width of the conveying platform 23 (if the width of the conveying platform 23 exceeds the width of the structured light belt 225, a multi-light source parallel covering method can be adopted).

[0077] As Figures 8 to 12 shown, a number of structured light belts 225 are symmetrically arranged and multi-angularly arranged in the manner shown in 8-a in Figure 8 , which can be evenly arranged on both sides of the CCD camera 21, and the arrangement angle range is 0 - 180°, and are projected onto the surface of the conveying platform 23 to form Figure 8 the pattern shown in 8-b in . This light source layout method can solve the problem of light source blind spots. For example, let the angle between the plate 9 and the conveying platform 23 be α, and the angle between the structured light belt 225 and the conveying platform 23 be β. When the angle α between the plate 9 and the conveying platform 23 is greater than the angle β between the structured light belt 225 and the conveying platform 23, the C area on the surface of the plate 9 can never be irradiated by the light source, thus forming a visual blind spot. After adopting the multi-angular and symmetrically arranged light sources in the present application, the structured light sources with different angles and symmetrically distributed can be used for irradiation simultaneously, and the light source blind spot during photographing can be eliminated.

[0078] The structured light optical system 22 includes a number of structured light sources symmetrically arranged on both sides of the CCD camera 21 along the movement direction of the plate 9. The structured light source includes a laser 221, a Powell prism 222, and a mask 223, and the mask 223 is installed below the Powell prism 222. The mask 223 is a rectangular mask 2231 or a mask with features 2233. Among them, a rectangular light passing area 2232 is provided on the rectangular mask 2231, and a light passing area with features 2234 is provided on the mask with features 2233, and feature graphic patterns 2235 such as feature grids are provided on its upper and lower edges, which can improve the recognition accuracy of the edge of the irradiation area of the structured light belt 225.

[0079] In addition, the present invention provides a working method for an intelligent sorting system, including the following steps:

[0080] S1. Loading: The plates 9 with model, size, and order number information pasted on them are sequentially placed into the conveying area of the loading mechanism 1, and the first code scanning mechanism 5 scans the plate information and transmits it to the control mechanism;

[0081] S2. Detection: The conveying mechanism 1 conveys the plate 9 to the detection area, and the detection mechanism 2 measures whether the size of the plate 9 and the position and size of the holes and grooves on the plate 9 meet the requirements, and conveys the plates 9 that meet the requirements to the storage and sorting mechanism 3, and rejects the plates that do not meet the requirements;

[0082] S3. Storage and sorting: The second barcode scanning mechanism 6 scans the information of the boards and transmits it to the control mechanism. The control mechanism controls the boards 9 that meet the requirements to be conveyed to the corresponding hoppers 37 of the storage and sorting mechanism 3. When all the boards 9 of the same order are stored completely, the control mechanism controls the different boards 9 of the same order to be continuously output to the palletizing area.

[0083] S4. Palletizing: The boards 9 conveyed to the palletizing area are stacked as required to complete the sorting of the boards with the same order number.

[0084] In addition, in the step S2, for the boards with holes and grooves on both sides, after being measured once, they return through the board return line 13, are flipped by the turning mechanism 7, and then enter the detection mechanism 2 again for measurement; for the boards 9 that meet the requirements, they are conveyed by the feeding conveyor line 14 to the corresponding hoppers 37 of the storage and sorting mechanism 3; for the boards 9 that do not meet the requirements, after passing through the board return line 13, they do not enter the turning mechanism 7 and are directly conveyed to the board recycling area.

[0085] In the step S2, the specific detection process includes the following steps:

[0086] S21. Install the CCD camera 21 and the structured light optical system 22, and the structured light optical system 22 is symmetrically distributed on both sides of the CCD camera 21.

[0087] S22. Generate the structured light. The process is as follows: Turn on the laser 221 in the structured light optical system 22, and make the laser beam generated by the laser 221 pass through the Powell prism 222 and the mask 223 in sequence. If the mask 223 is not installed, the light beam 224 with a certain width as shown in the figure generated directly by the laser beam passing through the Powell prism 222 has unclear upper and lower edges. In this application, a mask 223 is installed under the Powell prism 222. After the light beam 224 passes through the light-passing area on the mask 223, a structured light 225 with a specific size range and clear edges is generated. Figure 10 As shown in the figure, since the upper and lower edges of the generated light beam 224 are not clear enough, a mask 223 is installed under the Powell prism 222 in this application. After the light beam 224 passes through the light-passing area on the mask 223, a structured light 225 with a specific size range and clear edges is generated.

[0088] S23. Turn on the CCD camera 21 to obtain the four-dimensional coordinates of any point on the surface of the board 9. The process is as follows: Make the board 9 move forward at a certain speed on the conveying platform 23. The CCD camera 21 continuously scans and takes pictures to obtain the two-dimensional image of the surface of the board 9 and transmits it to the control mechanism. The control mechanism processes the information after receiving the image, obtains the three-dimensional coordinates of any point on the surface of the board 9, and obtains the four-dimensional coordinates of any point on the surface of the board 9 by superimposing the gray values of each point in the image.

[0089] Preferably, in step S22, the generated structured light 225 is a parallel strip-shaped laser line with a width of 5-20 mm, and the contours of its upper and lower edges are clear and the straightness is less than 0.1 mm, which is specifically selected according to the measurement accuracy requirements.

[0090] When manufacturing the structured light 225 in this application, a mask 223 is installed below the Powell prism 222. By changing the dimensions of the light-passing area on the mask 223, the size range of the structured light 225 irradiated on the surface of the plate 9 is determined, and at the same time, clear and accurate contours of the upper and lower edges of the structured light 225 are obtained.

[0091] As Figures 13 to 17 shown, in step S23, the process of obtaining the three-dimensional coordinates of any point on the surface of the plate is as follows: By combining the width, incident angle of the structured light 225 and the coordinates projected on the surface of the conveying platform 3 in theory with the projected width and projected coordinates of the structured light 225 in the two-dimensional image, the three-dimensional coordinates of the projected edge contour are calculated based on the calibration data of the CCD camera 21; By symmetrically arranging a number of structured lights 225 on both sides of the CCD camera 21 at different angular postures, the three-dimensional coordinates of several lines on the surface of the plate 9 can be obtained, and the three-dimensional coordinates (X, Y, Z) of any point on the surface of the plate 9 are obtained through mathematical fitting. The four-dimensional coordinates are (X, Y, Z, P), where P is the gray value, and the gray value is obtained from the brightness of the structured light in the two-dimensional image.

[0092] The specific derivation process is as follows: Taking one structured light 225 as an example, when the structured light 225 directly irradiates the surface of the conveying platform 23, the angle between the structured light 225 and the conveying platform 23 in the Figure 13 shown XOZ coordinate system is θ1, and the X-axis coordinates of the upper and lower edges of the structured light 225 obtained in the CCD camera 21 are X a and X b , and the Z coordinate is 0.

[0093] When the plate 9 to be measured passes through the structured light 225, the X coordinates of the front and rear edges of the structured light 225 are X a1 and X b1 , and the corresponding Z coordinates are respectively:

[0094] Za1=(X a -X a1 )*tan(θ1)

[0095] Zb1=(X b -X b1 )*tan(θ1)

[0096] For multiple structured lights 225, there is a fixed distance relationship for their X-axis coordinates. The included angles between two structured lights 225 are θ1 and θ2 respectively, and the basic coordinates are Xa , X b and X c , X d , the coordinate systems of the images obtained by scanning with two structured light strips 225 can be unified into one coordinate system.

[0097] Based on the continuous scanning of multiple structured light strips 225 by the CCD camera 21, a three-dimensional contour curve as shown in Figure 16 can be obtained. By increasing the number of structured light strips 225 and reducing the scanning speed, the density of the contour lines can be increased and the measurement accuracy can be improved.

[0098] Among them, the two-dimensional image information captured by the camera includes three parameters (U, V, P). Among them, U and V are pixel coordinates, and P is the gray value of this pixel point. By calibrating to obtain the conversion matrix R from pixels to the world coordinate system, (X, Y, Z) = (U, V, θ1)R can be obtained. Further introducing the gray value P of this point, the four-dimensional data (X, Y, Z, P) = (U, V, θ1, P)R of each point on the edge curve of the structured light strip 225 is obtained.

[0099] For the physical coordinates of the internal image of the upper and lower edges of the structured light strip 225, the spatial spline curve fitting method is used for calculation. C is any point inside the edge contour line, and the intersection points N1(X1, Y, Z1), N2(X2, Y, Z2), N3(X3, Y, Z3), N4(X4, Y, Z4) of the plane with the same Y value of the screenshot and each edge contour line are obtained by fitting with a cubic spline curve respectively.

[0100] The gray value calculation process is as shown in Figure 17 . It is known that points a and b are adjacent pixel points, and their pixel coordinates are (U a , V a , P a ) and (U b , V b , P b ). The corresponding physical point A coordinates are (X a , Y a , Z a , P a ) and B coordinates are (X b , Y b , Z b , P b ). For the world coordinates of C are (X c , Y c , Z c ), the gray value calculation method of its projection point c is as follows: P = (Z C - Z A ) / (Z B - Z A ) * (P b - P a ).

[0101] In addition, in step S3, the storage and sorting process is as follows:

[0102] The control mechanism plans the hopper 37 corresponding to each plate 9 and the storage position in the hopper 37 according to the plate information, and controls the operation of the driving component 32. The driving component 32 drives the hopper 37 to rotate in the vertical direction along the annular guide rail 35 through the transmission component 33, so that the corresponding hopper 37 is driven to the feed port 38 according to the planned path, and the feed push plate component 19 pushes the plate 9 to the corresponding position of the hopper 37; when the control mechanism recognizes that the plates of the same order have been stored, it controls the corresponding hopper 3 to rotate to the discharge port, and the discharge push plate component 34 continuously outputs different plates 9 of the same order to the discharge conveyor line 15, and transports them to the stacking area for stacking, completing the sorting of plates with the same order number.

[0103] Preferably, during the storage and sorting process, according to the different sizes of each plate 9, the material blocking cylinder in the material blocking assembly 18 controls the material blocking baffle 181 to rise or fall so as to restrict each plate 9 to different workstations and enter different positions in the hopper 37.

[0104] In addition, since the wire tube of the feed conveyor line 14 is a rubber wire tube, the friction coefficient is relatively large, and the wire tube is not easy to replace, in order to reduce the wear of the wire tube caused by the friction force generated when the plate 9 is directly pushed into the sub-hopper layer 373 on the wire tube, during feeding, when the plate 9 is conveyed to the corresponding position of the feed port 38, the material blocking cylinder controls the material blocking baffle 181 to rise, restricting each plate 9 to different stations, and then the wear-resistant cylinder controls the wear-resistant plate 171 to rise, so that the wear-resistant plate 171 lifts the plate 9 to the wire tube that is separated from the feed conveyor line 14. Then the feed cylinder corresponding to each station controls the feed push plate 191 to simultaneously push each plate 9 on the wear-resistant plate 171 to different positions in the sub-hopper layer 373 to store the plate 9.

[0105] During discharging, the wear-resistant cylinder on the discharging conveyor line 15 controls the wear-resistant plate 171 to rise, and the discharging cylinder controls the discharging push plate 341 to push the plate 9 in the sub-hopper layer 3763 onto the wear-resistant plate 171 of the discharging conveyor line 15 .

[0106] In the present disclosure, the directions or positional relationships indicated by terms such as "upper", "lower", "left", "right", etc. are based on the directions or positional relationships shown in the accompanying drawings. They are relational words determined only for the convenience of describing the structural relationships of the various parts of the present disclosure and are not to be understood as limitations on the present disclosure.

[0107] The above-described embodiments merely represent several implementation manners of the present invention. The description thereof is relatively specific and detailed, but it should not be construed as a limitation to the scope of the invention patent. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present invention, several modifications and improvements can still be made, and these all fall within the protection scope of the present invention.

Claims

1. An intelligent sorting system, characterized in that, It includes a conveying mechanism (1), a detection mechanism (2), a storage and sorting mechanism (3), a palletizing mechanism (4) and a control mechanism. A first barcode scanning mechanism (5) and a second barcode scanning mechanism (6) are respectively provided at the input ends of the detection mechanism (2) and the storage and sorting mechanism (3). The conveying mechanism (1) is used for conveying the board (9), and it includes a conveying support and a loading area, a detection area, a storage and sorting area, and a palletizing area that are sequentially arranged on the conveying support. The loading area is provided with a loading conveyor line (11), the detection area is provided with a detection conveyor line (12) and a board return line (13), the storage and sorting area is provided with a feeding conveyor line (14), an unloading conveyor line (15) and a feeding push plate assembly (19). The feeding push plate assembly (19) is used to push the board (9) on the feeding conveyor line (14) into the storage and sorting mechanism (3). The palletizing area is provided with a palletizing conveyor line (16). The loading conveyor line (11), the detection conveyor line (12) and the feeding conveyor line (14) are sequentially connected. The unloading conveyor line (15) is connected to the palletizing conveyor line (16). The board return line (13) is correspondingly arranged on one side of the detection conveyor line (12) and is connected to the detection conveyor line (12). The detection mechanism (2) is correspondingly arranged above the detection area of the conveying mechanism (1), and it is used to detect the board (9) on the conveying mechanism (1). The detection mechanism (2) includes a CCD camera (21) and a structured light optical system (22). When the board (9) to be detected is conveyed on the conveying mechanism (1), the CCD camera (21) is used to capture the surface image of the board (9), and the structured light optical system (22) is used to generate a plurality of structured lights (225) that are symmetrically arranged at different angular postures on both sides of the CCD camera (21) along the movement direction of the board (9). The storage and sorting mechanism (3) is correspondingly arranged on one side of the storage and sorting area of the conveying mechanism (1), and it is used to sort and store the board (9). The storage and sorting mechanism (3) includes a sorting rack, a driving component (32), a transmission component (33), an annular guide rail (35), a plurality of hoppers (37), an unloading push plate assembly (34), a feeding port (38) and an unloading port (31) that are arranged on the sorting rack. The transmission component (33) is fixedly connected to the hopper (37). The driving component (32) drives the hopper (37) to rotate vertically along the annular guide rail (35) through the transmission component (33) to drive each hopper (37) to the feeding port (38) or the unloading port (31). The feeding port (38) and the unloading port (31) are respectively correspondingly arranged with the feeding conveyor line (14) and the unloading conveyor line (15). The unloading push plate assembly (34) is correspondingly arranged with the unloading port (31) to push the board (9) in the hopper (37) to the unloading conveyor line (15). The palletizing mechanism (4) is correspondingly arranged at the output end of the palletizing area and is used for palletizing and dividing the boards (9) on the palletizing conveyor line (16). It includes a palletizing machine frame (41) and a suction cup assembly (42) arranged on the palletizing machine frame (41). The suction cup assembly (42) is connected to the palletizing machine frame (41) through a three-dimensional motion assembly (43); The control mechanism is connected to the conveying mechanism (1), the detection mechanism (2), the storage and sorting mechanism (3) and the palletizing mechanism (4), and controls the operation of each mechanism; A number of material blocking assemblies (18) are arranged on the feeding conveyor line (14). The material blocking assembly (18) includes a material blocking cylinder and a material blocking baffle (181) connected to the material blocking cylinder. The material blocking cylinder drives the material blocking baffle (181) to move up and down to limit the boards on the feeding conveyor line (14) so that they are pushed into the hopper (37) at different workstations; The working process of the intelligent sorting system includes the following steps: S1. Loading: The boards (9) with model, size, and order number information are successively placed in the conveying area of the conveying mechanism (1). The first barcode scanning mechanism (5) scans the board information and transmits it to the control mechanism; S2. Detection: The conveying mechanism (1) conveys the board (9) to the detection area. The detection mechanism (2) measures the size of the board (9) and whether the positions and sizes of the holes and grooves on the board (9) meet the requirements, and conveys the boards (9) that meet the requirements to the storage and sorting mechanism (3), and rejects the boards (9) that do not meet the requirements. The detection process includes the following steps: S21. Install the CCD camera (21) and the structured light optical system (22). The structured light optical system (22) is symmetrically distributed on both sides of the CCD camera (21); S22. Produce structured light. The process is as follows: Turn on the laser (221) in the structured light optical system (22), and sequentially pass the laser beam generated by the laser (221) through the Powell prism (222) and the mask (223) to generate structured light (225) with a specific size range and clear edges. The structured light (225) is a parallel strip-shaped laser line with a width of 5-20 mm, and the contours of its upper and lower edges are clear and the straightness is less than 0.1 mm; S23. Turn on the CCD camera (21) to obtain the four-dimensional coordinates of any point on the surface of the board (9). The process is as follows: Make the board (9) to be measured move forward at a certain speed on the conveying platform (23). The CCD camera (21) continuously scans and takes pictures to obtain the two-dimensional image of the surface of the board (9) and transmits it to the control mechanism. After receiving the image, the control mechanism performs information processing to obtain the three-dimensional coordinates of any point on the surface of the board (9), and obtains the four-dimensional coordinates of any point on the surface of the board (9) by superimposing the gray values of each point in the image; The process of obtaining the three-dimensional coordinates of any point on the surface of the sheet (9) is as follows: By combining the width of the structured light (225), the incident angle, and the theoretically projected coordinates on the conveying platform (23) with the projected width and projected coordinates of the structured light (225) in the two-dimensional image, the three-dimensional coordinates of the projected edge contour are calculated based on the calibration data of the CCD camera (21); By arranging a number of structured lights (225) symmetrically on both sides of the CCD camera (21) at different angular postures, the three-dimensional coordinates of several lines on the surface of the sheet can be obtained, and the three-dimensional coordinates (X, Y, Z) of any point on the surface of the sheet (9) to be measured are obtained through mathematical fitting. The four-dimensional coordinates are (X, Y, Z, P), where P is the gray value, and the gray value is obtained from the brightness of the structured light in the two-dimensional image; S3. Storage and sorting: The second barcode scanning mechanism (6) scans the sheet information and transmits it to the control mechanism. The control mechanism controls each qualified sheet (9) to be conveyed into the corresponding hopper (37) of the storage and sorting mechanism (3). When all the sheets (9) of the same order are stored completely, the control mechanism controls the different sheets of the same order to be continuously output to the palletizing area; S4. Palletizing: Stack the sheets (9) conveyed to the palletizing area as required to complete the sorting of the sheets with the same order number.

2. The intelligent sorting system according to claim 1, wherein Both ends of the sheet return line (13) are connected to the inspection conveying line (12), and a flap mechanism (7) is provided between the sheet return line (13) and the inspection conveying line (12).

3. An intelligent sorting system according to claim 1, characterized in that, Both the feeding push plate assembly (19) and the discharging push plate assembly (34) are provided with two or more.

4. An intelligent sorting system according to claim 1, characterized in that, A number of wear-resistant components (17) are provided on both the feeding conveying line (14) and the discharging conveying line (15). The wear-resistant components (17) on the feeding conveying line (14) are arranged corresponding to the feeding port (38), and the wear-resistant components (17) on the discharging conveying line (15) are arranged corresponding to the discharging port (31); The wear-resistant component (17) includes a lifting cylinder and a wear-resistant plate (171) connected to the lifting cylinder. The lifting cylinder drives the wear-resistant plate (171) to lift and lower, so that the sheet (9) can be conveyed on the wear-resistant plate (171).

5. An intelligent sorting system according to claim 1, characterized in that, The control mechanism can control the hopper (37) to rotate clockwise or counterclockwise.

6. An intelligent sorting system according to claim 1, characterized in that, The hopper (37) is divided into several sub-hopper layers.

7. An intelligent sorting system according to claim 1, characterized in that, A number of the structured lights (225) are evenly distributed on both sides of the CCD camera (21), and the layout angle range is 0 - 180°. The structured light optical system (22) includes a number of structured light sources symmetrically arranged on both sides of the CCD camera (21) along the movement direction of the sheet (9). The structured light source includes a laser (221), a Powell prism (222), and a mask (223). The mask (223) is installed below the Powell prism (222), and the mask (223) is a rectangular mask (2231) or a feature-bearing mask (2233).

8. An intelligent sorting system according to claim 1, characterized in that, In the step S2, for the plate (9) with holes and grooves on both sides, after one measurement, it returns through the plate return line (13), and after being flipped by the turning plate mechanism (7), it enters the detection mechanism (2) again for measurement; for the qualified plates (9), they are conveyed by the feeding conveyor line (14) to the corresponding hoppers (37) of the storage and sorting mechanism (3); for the unqualified plates (9), they are conveyed through the plate return line (13) to the recycling area for rejection.

9. An intelligent sorting system according to claim 1, wherein In the step S3, the storage and sorting process is as follows: The control mechanism plans the corresponding hoppers (37) for each plate (9) and their storage positions in the hoppers (37) according to the plate information, and controls the driving component (32) to work. The driving component (32) drives the hoppers (37) to rotate vertically along the circular guide rail (35) through the transmission component (33), so that the corresponding hoppers (37) are driven to the feeding port (38) along the planned path. The feeding push plate component (19) pushes the plate (9) into the corresponding position of the hopper (37); when the control mechanism recognizes that all the plates (9) of the same order have been stored, it will control the corresponding hopper (37) to rotate to the discharging port (31), and the discharging push plate component (34) continuously outputs different plates (9) of the same order to the discharging conveyor line (15) and conveys them to the stacking area for stacking, completing the sorting of the plates (9) with the same order number.

10. An intelligent sorting system according to claim 9, characterized in that, During the storage and sorting process, according to the different sizes of the plates (9), the blocking cylinder in the blocking component (18) controls the blocking baffle (181) to rise or fall to limit each plate (9) at different workstations and into different positions in the hopper (37).

Images