An intelligent package-handling system for large packaging production lines

Abstract

The present invention provides an intelligent package-handling system for large-scale packaging production lines. The system comprises a first detection unit connected to a control unit for detecting the position information of a first item; a second detection unit connected to the control unit for detecting the position information of a second item; a control unit connected to a drive adjustment unit for generating a control instruction based on the received first and second item position information and transmitting the control instruction to the drive adjustment unit; a drive adjustment unit connected to a drive unit for adjusting and controlling the drive unit according to the instruction of the control unit; and a drive unit configured to drive a transmission system connected to the first item and adjust the transmission speed of the transmission system according to the control information from the drive adjustment unit. The present invention has the advantages of preventing package overlap, increasing the success rate of package handover, and saving time and effort.

Description

Technical Field

[0001] The present invention relates to the field of production line transmission systems, and in particular to an intelligent package delivery system for large packaging production lines. Background Art

[0002] After being packaged on the production line, large packages are transported to the designated location via conveyor belts. If there are multiple production lines, the large packages packaged on each production line are transported separately via the conveyor belts on their respective production lines and then aggregated onto a central conveyor belt, which then transports them to the designated location.

[0003] When the items on the existing multiple production line conveyor belts, such as three, are aggregated onto a single conveyor belt, improper bag placement often results in overlapping and damaged bags, affecting production efficiency. The existing technical solutions have the following disadvantages:

[0004] (1) When the transmission belts of multiple production lines cannot be stopped, overlapping often occurs on the total transmission belt during aggregation, affecting the normal operation of the process;

[0005] (2) The possibility of bag rot increases after stacking, which significantly reduces product quality and efficiency;

[0006] (3) The manual bagging method results in high labor intensity, time-consuming and labor-intensive, and lacks precision. Summary of the Invention

[0007] In order to solve the problems existing in the background technology, the present invention proposes an intelligent package-handling system for large-scale packaging production lines.

[0008] An intelligent package-handling system for large packaging production lines, including

[0009] a first detection unit configured to be connected to the control unit and configured to detect position information of the first object;

[0010] a second detection unit configured to be connected to the control unit and configured to detect position information of a second object;

[0011] a control unit configured to be connected to the driving and regulating unit, and configured to generate a control instruction based on the received first object position information and the second object position information, and send the control instruction to the driving and regulating unit;

[0012] a drive adjustment unit, configured to be connected to the drive unit and used to adjust and control the drive unit according to instructions from the control unit;

[0013] The driving unit is configured to drive the transmission system connected to the first object and to adjust the transmission speed of the transmission system according to the control information of the driving adjustment unit.

[0014] Based on the above, the first detection unit includes a first mirror-reflective photoelectric sensor and a reflective mirror. The first photoelectric sensor is arranged on one side of the production line transmission system close to the material incoming direction of the total transmission system corresponding to the total transmission system, and the reflective mirror is arranged on the other side of the total transmission system corresponding to the first photoelectric sensor; the first photoelectric sensor is connected to the control unit.

[0015] Based on the above, the second detection unit includes a diffuse reflection type second photoelectric sensor, the second photoelectric sensor is arranged on one side of the production line transmission system, and the second photoelectric sensor is connected to the control unit.

[0016] Based on the above, the control unit includes a PLC controller, the drive adjustment unit is a frequency converter, the drive unit is a drive motor, the PLC controller is connected to the drive motor through the frequency converter control, and the drive motor is used to drive the overall transmission system.

[0017] Based on the above, the control unit controls the transport system of the first object to accelerate or decelerate for a certain period of time according to the position information of the first object and the position information of the second object.

[0018] Based on the above, the item location information on the production line transmission system detected by the second detection unit is a lock package signal with a certain duration, and the lock package signal is divided into a first section, a second section and a third section according to the duration. After the first detection unit detects the item location information on the total transmission system, if the lock package signal is in the first section, the total transmission system is controlled to accelerate for a certain period of time; if the lock package signal is in the second section, the total transmission system is controlled to run at normal speed; if the lock package signal is in the third section, the total transmission system is controlled to decelerate for a certain period of time.

[0019] Based on the above, when two production lines need to release packages at the same time, if one package lock signal is in the first section and the other package lock signal is in the first section or the second section, the overall transmission system is controlled to accelerate for the set time; if both package lock signals are in the second section, the overall transmission system is controlled to run at normal speed; if one package lock signal is in the third section and the other package lock signal is in the second section or the third section, the overall transmission system is controlled to decelerate for the set time; if one package lock signal is in the first section and the other package lock signal is in the third section, the overall transmission system is controlled to accelerate or decelerate for the set time based on the section in which the package lock signal detected first is located.

[0020] Based on the above, the control unit further includes a switching unit and a jog switch. The switching unit is connected to the PLC controller, and the PLC controller switches the control mode according to the switching unit; the jog switch controls the connection to the frequency converter.

[0021] Based on the above, an indicator light is included, and the inverter controls the connection to the indicator light.

[0022] Based on the above, it includes a protection bypass, which includes an emergency stop switch, an intermediate relay, a bypass contactor and a bypass motor protector. The emergency stop switch controls the connection to the intermediate relay, the contacts of the intermediate relay control the connection to the bypass contactor, and the contacts of the bypass contactor control the connection to the main circuit of the bypass motor protector.

[0023] The present invention has outstanding substantive features and significant progress compared to the prior art. Specifically:

[0024] 1. The present invention detects the position of items on the production line transmission system and the position of items on the main transmission system, and controls the main transmission system to accelerate or decelerate for a certain period of time according to the position information, thereby achieving package clearance and fully avoiding the phenomenon of package overlap, thereby avoiding package damage and rework caused by package overlap;

[0025] 2. After the present invention realizes intelligent bag-passing, the production line will no longer be shut down due to bag overlap, thus ensuring the continuity of product quality (such as bag sewing and coding) and production efficiency;

[0026] 3. The present invention realizes intelligent baggage transfer, eliminating the need for manual baggage transfer, thus reducing manpower and costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a structural schematic diagram of the present invention.

[0028] Figure 2 It is a schematic diagram of the top structure of the transmission system and detection unit of the present invention.

[0029] Figure 3 It is a circuit structure diagram of the controller and the frequency converter of the present invention.

[0030] Explanation of the reference numerals: 1, 1# line transmission belt; 2, 2# line transmission belt; 3, 3# line transmission belt; 4, main transmission belt; 5, first sensor of 2# line; 6, reflecting mirror of 2# line; 7, second sensor of 2# line. DETAILED DESCRIPTION

[0031] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without creative work are within the scope of protection of the present invention.

[0032] like Figure 1As shown, a large packaging production line aggregates intelligent package delivery system, including a first detection unit, configured to be connected to a control unit, for detecting the position information of a first object; a second detection unit, configured to be connected to a control unit, for detecting the position information of a second object; a control unit, configured to be connected to a drive adjustment unit, for generating a control instruction based on the received first object position information and second object position information, and sending the control instruction to the drive adjustment unit; a drive adjustment unit, configured to be connected to a drive unit, for adjusting and controlling the drive unit according to the instruction of the control unit; and a drive unit, configured to drive a transmission system connected to the first object, for adjusting the transmission speed of the transmission system according to the control information of the drive adjustment unit.

[0033] During use, the first detection unit detects the position information of the items on the total transmission system, that is, the position information of the first item, and the second detection unit detects the position information of the items on the production line transmission system, that is, the position information of the second item. The first detection unit and the second detection unit are matched with each other. When the first detection unit and the second detection unit both detect items, the control unit controls the drive adjustment unit to adjust the drive unit, and the drive unit drives the total transmission system to accelerate or decelerate for a certain period of time, so that the items on the total transmission system are accelerated to pass through the docking point between the production line transmission system and the total transmission system, so as to avoid the items on the production line transmission system from colliding with the items on the total transmission system when they arrive at and enter the total transmission system, thereby realizing intelligent bagging of items on the total transmission system and items on the production line transmission system to avoid overlapping and collision.

[0034] Specifically, take three production line transmission systems and one total transmission system as an example. Figure 2 As shown, the overall transmission system is a total transmission belt system. The production line transmission system includes the 1# production line transmission belt system, the 2# production line transmission belt system, and the 3# production line transmission belt system. The 1# production line transmission belt 1, the 2# production line transmission belt 2, and the 3# production line transmission belt 3 are sequentially arranged along the feed direction of the total transmission belt 4. Therefore, the items on the 1# production line transmission belt 1 do not need to be moved. Only the 2# production line transmission belt system and the 3# production line transmission belt system need to be moved. That is, products on the 2# production line avoid products on the 1# production line on the total transmission belt, and products on the 3# production line avoid products on the 1# and 2# production lines on the total transmission belt. In this embodiment, the control unit includes a PLC controller, model FX1S-10MT, the drive adjustment unit is a frequency converter LS, model SV075iG5A, and the drive unit is a drive motor. The PLC controller controls the drive motor through the frequency converter, and the drive motor is used to drive the overall transmission system. The transmission speed of the production line transmission system cannot be changed, otherwise it will affect the operation of other equipment on the production line, such as the bag sewing equipment and inkjet printer.

[0035] A first photoelectric sensor 5 is mounted on the side of the conveyor belt of the production line 2, or the line 2 conveyor belt, near the incoming material direction of the main conveyor system. This first photoelectric sensor is a mirror-reflective type, model E3JK-RR12-C in this embodiment. A reflective mirror 6 is positioned opposite the first photoelectric sensor 5 from the main conveyor belt. Furthermore, a second photoelectric sensor 7 is mounted on the side of the line 2 conveyor belt. This second photoelectric sensor is a diffuse-reflective type, model QS18VN6D in this embodiment. During normal operation, the photoelectric signal emitted by the first photoelectric sensor is reflected by the reflective mirror and then received by the first photoelectric sensor. The signal emitted by the second photoelectric sensor cannot be reflected back, resulting in no feedback signal under normal conditions. When an item passes by the first photoelectric sensor on the main conveyor belt, it fails to receive the reflected signal. The controller then determines that an item on the main conveyor belt is about to reach the junction between the line 2 conveyor belt and the main conveyor belt. When an item on the production line's conveyor belt passes the second photoelectric sensor, the second photoelectric sensor receives a feedback signal due to the item's reflection. The controller then determines that an item on the production line's conveyor belt is about to arrive at the main conveyor system. If both the first and second photoelectric sensors detect an item simultaneously—that is, if the first sensor has no feedback signal and the second sensor has a feedback signal—this indicates that a package overlap or collision may have occurred. The controller then uses the frequency converter to adjust the main conveyor system's drive motor to accelerate or decelerate for a certain period of time. This accelerates or decelerates the item on the main conveyor belt as it passes through the junction of Line 2. This prevents items on Line 2 from colliding with items on the main conveyor system upon reaching and entering the main conveyor system, thereby achieving intelligent package clearing. The structure and operating principle of Line 3 are similar to those of Line 2 and will not be further described here. In practice, the acceleration or deceleration time can be set as needed. In this embodiment, the acceleration or deceleration time is set to 1 second. In other embodiments, it can be set to 1.5 seconds, 2 seconds, or other times depending on actual needs. The position of the first photoelectric sensor and the position of the second photoelectric sensor are set according to the power frequency operating speed of the total transmission belt and the power frequency operating speed of the production line transport belt, respectively. At the same time, the acceleration or deceleration amplitude is set according to the position of the first photoelectric sensor and the position of the second photoelectric sensor and the power frequency speed of the transport belt to ensure that the acceleration or deceleration process of one second can achieve package release.

[0036] In this embodiment, the item location information on the production line transmission system detected by the second detection unit is a package lock signal with a certain duration. For example, the package lock signal detected by the 2# and 3# transmission systems. Since the package sizes are uniform, each package lock signal lasts for 1 second. The package lock signal is divided into a first segment, a second segment, and a third segment according to its duration. The first segment is the first one-third of a second time period of the package lock signal, the second segment is the middle one-third of a second time period of the package lock signal, and the third segment is the last one-third of a second time period of the package lock signal. When both the first detection unit and the second detection unit detect signals, if the package lock signal is in the first segment, the overall transmission system is controlled to accelerate for a certain period of time. If the package lock signal is in the second segment, the overall transmission system is controlled to operate at normal speed. If the package lock signal is in the third segment, the overall transmission system is controlled to decelerate for a certain period of time. Line 2# and line 3# need to release packets simultaneously, that is, when the first and second detection units of line 2# and the first and second detection units of line 3# detect signals simultaneously, if one lock packet signal is in the first segment and the other lock packet signal is in the first segment or the second segment, the overall transmission system is controlled to accelerate for a set time, such as 1 second; if both lock packet signals are in the second segment, the overall transmission system is controlled to operate at normal speed; if one lock packet signal is in the third segment and the other lock packet signal is in the second segment or the third segment, the overall transmission system is controlled to decelerate for a set time, such as 1 second; if one lock packet signal is in the first segment and the other lock packet signal is in the third segment, the overall transmission system is controlled to accelerate or decelerate for a set time, such as 1 second, based on the segment in which the lock packet signal detected first is located. That is, if the lock packet signal detected first is in the first segment, the overall transmission system is controlled to accelerate for a set time, such as 1 second; if the lock packet signal detected first is in the third segment, the overall transmission system is controlled to decelerate for a set time, such as 1 second. In practice, the inverter control is connected to alarm devices such as indicator lights and buzzers. If, when three production lines are running simultaneously, Lines 2 and 3 simultaneously or repeatedly fail to release a package, the inverter accelerates the drive motor of the main transmission belt three times in a row. The inverter then activates an indicator light or buzzer to sound an alarm, prompting manual intervention. In this embodiment, a 100% success rate for releasing a package can be achieved with two production lines running simultaneously, and a success rate of over 90% for all three production lines running simultaneously.

[0037] like Figure 3As shown, the control unit also includes a switching unit, which is connected to the PLC controller, and the PLC controller switches the control mode according to the switching unit. The switching unit includes a switching switch SB1, a momentary switch SB3 and an alarm reset button SB2. The switching switch SB1 is used to switch between the automatic package-giving mode and the manual package-giving mode. When the automatic package-giving mode is selected, the X4 terminal of the PLC controller is connected to the COM terminal of the PLC controller and forms an electrical circuit. The COM terminal is at a low level, the relay KA1 is energized, the normally open contact of the relay KA1 is closed, and the contactor KM1 (the coil of the contactor KM1 is at Figure 3 Not shown, in this embodiment, the contactor KM1 is connected in series in the power supply system. When the system is powered on, that is, when the system main switch is closed, the contact of the contactor KM1 is energized and closed. The FX terminal of the LS inverter is connected to the CM terminal of the PLC controller to form an electrical circuit. The CM terminal is at a low level, and the inverter automatically controls the drive motor according to the signal from the P1 terminal, P2 terminal or P3 terminal. At this time, the operation relay relay KA2 is energized, the normally open contact of the relay KA2 is closed, and the on-site operation indicator PG1 and the remote operation indicator (i.e. Figure 3 The Yellow light of the LS inverter is on. The B port of the LS inverter normally outputs a high level, and the running indicator light (i.e. Figure 3 The Green light of the port is normally on. When a fault occurs or the device accelerates continuously, the power to the B port is cut off and the running indicator light goes out. At the same time, the A port outputs a high level and the running indicator light and buzzer connected to the A port (i.e. Figure 3 After the fault is cleared, reset the inverter by pressing the alarm reset button SB2. KF1 is the first photoelectric sensor signal of line 2#, KF3 is the second photoelectric sensor signal of line 2#, KF2 is the first photoelectric sensor signal of line 3#, and KF4 is the second photoelectric sensor signal of line 3#. Figure 3 Terminals BK1-BK4 are grounded. The PLC controller's Y0 outputs a signal to the inverter, causing the main transmission belt's drive motor to decelerate. Output terminal Y1 also outputs a signal to the inverter, causing the main transmission belt's drive motor to operate at normal power frequency. Output terminal Y2 also outputs a signal to the inverter, causing the main transmission belt's drive motor to accelerate. When manual handover mode is selected, terminal X5 of the PLC controller is connected, relay KA1 is de-energized, and manual control is performed via inching switch SB3.

[0038] Preferably, the intelligent packaging system for the large packaging production line includes a protection bypass, which includes an emergency stop switch, an intermediate relay, a bypass contactor and a bypass motor protector. The emergency stop switch controls the connection to the intermediate relay, and the contact of the intermediate relay controls the connection to the bypass contactor. The normally closed contact of the bypass contactor controls the connection to the main circuit of the bypass motor protector. When the frequency converter fails, the emergency stop switch SB4 is disconnected, the power to the frequency converter FX end is cut off, and the frequency converter stops working. After the emergency stop switch SB4 is disconnected, the relay KA3 is de-energized, the normally open contact of the relay KA3 is disconnected, the bypass contactor KM2 is de-energized, and the normally closed contact of the bypass contactor KM2 (connected in the circuit of the bypass motor protector) is disconnected. Figure 3 When the emergency stop switch SB4 (not shown) is closed, the bypass motor protector operates. This allows the drive motor to continue operating at its original power frequency mode if the inverter fails and cannot be restored promptly, thus preventing disruption to normal production. When the emergency stop switch SB4 is closed, contactor KM2 is energized, the normally closed contact opens, and the bypass motor protector stops operating, allowing normal inverter control.

[0039] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

Claims

1. An intelligent package delivery system for large packaging production lines, characterized by: include a first detection unit configured to be connected to the control unit and configured to detect position information of the first object; a second detection unit configured to be connected to the control unit and configured to detect position information of a second object; a control unit configured to be connected to the driving and regulating unit, and configured to generate a control instruction based on the received first object position information and the second object position information, and send the control instruction to the driving and regulating unit; a drive adjustment unit, configured to be connected to the drive unit and used to adjust and control the drive unit according to instructions from the control unit; a driving unit configured to drive a transmission system connected to the first article and to adjust a transmission speed of the transmission system according to control information from the driving adjustment unit; The item position information on the production line transmission system detected by the second detection unit is a package lock signal with a certain duration, and the package lock signal is divided into a first section, a second section and a third section according to the duration; when two production lines need to release packages at the same time, if one package lock signal is in the first section and the other package lock signal is in the first section or the second section, the overall transmission system is controlled to accelerate for the set time; if both package lock signals are in the second section, the overall transmission system is controlled to run at a normal speed; if one package lock signal is in the third section and the other package lock signal is in the second section or the third section, the overall transmission system is controlled to decelerate for the set time; if one package lock signal is in the first section and the other package lock signal is in the third section, the overall transmission system is controlled to accelerate or decelerate for the set time according to the section in which the package lock signal detected first is located.

2. The intelligent package-handling system for large packaging production lines according to claim 1 is characterized by: The first detection unit includes a first mirror-reflective photoelectric sensor and a reflective mirror. The first photoelectric sensor is arranged on one side of the production line transmission system close to the material incoming direction of the total transmission system, corresponding to the total transmission system, and the reflective mirror is arranged on the other side of the total transmission system corresponding to the first photoelectric sensor; the first photoelectric sensor is connected to the control unit.

3. The intelligent package-handling system for large packaging production lines according to claim 1 is characterized by: The second detection unit includes a diffuse reflection type second photoelectric sensor, the second photoelectric sensor is arranged on one side of the production line transmission system, and the second photoelectric sensor is connected to the control unit.

4. The intelligent package-handling system for large packaging production lines according to claim 1 is characterized by: The control unit includes a PLC controller, the drive adjustment unit is a frequency converter, the drive unit is a drive motor, the PLC controller is connected to the drive motor through the frequency converter, and the drive motor is used to drive the overall transmission system.

5. The intelligent package-handling system for large packaging production lines according to claim 1 is characterized by: The control unit controls the transport system of the first object to accelerate for a certain period of time or decelerate for a certain period of time according to the position information of the first object and the position information of the second object.

6. The intelligent package-handling system for large packaging production lines according to claim 5 is characterized by: After the first detection unit detects the item location information on the total transmission system, if the package lock signal is in the first section, the total transmission system is controlled to accelerate for a certain period of time; if the package lock signal is in the second section, the total transmission system is controlled to run at normal speed; if the package lock signal is in the third section, the total transmission system is controlled to decelerate for a certain period of time.

7. The intelligent package-handling system for large packaging production lines according to claim 4 is characterized by: The control unit further includes a switching unit and a jog switch. The switching unit is connected to the PLC controller, and the PLC controller switches the control mode according to the switching unit; the jog switch controls the connection to the frequency converter.

8. The intelligent package-handling system for large packaging production lines according to claim 4 is characterized by: An indicator light is included, and the frequency converter controls the connection to the indicator light.

9. The intelligent package-handling system for large packaging production lines according to claim 4, characterized in that: It includes a protective bypass, which includes an emergency stop switch, an intermediate relay, a bypass contactor and a bypass motor protector. The emergency stop switch controls the connection to the intermediate relay, the contacts of the intermediate relay control the connection to the bypass contactor, and the contacts of the bypass contactor control the connection to the main circuit of the bypass motor protector.

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