A method for preventing jamming at the material gate of a pellet counting machine and the pellet counting machine

Abstract

This invention discloses a method for preventing jamming at the feed gate of a pellet counter and the feed gate itself. The feed gate is connected to the extended end of the mover of a corresponding linear motor, and the servo driver of the linear motor is connected to a controller. The method for preventing jamming at the feed gate includes: counting the number of pellets passing through each feed gate; when the number of pellets reaches a set value, controlling the feed gate to extend via the corresponding linear motor to block the pellets from falling; simultaneously monitoring the real-time torque value of the linear motor; when the real-time torque value is greater than or equal to a jamming torque set value, and the duration is greater than a time set value, immediately controlling the feed gate to retract via the corresponding linear motor, and marking the current pelleting container and the next pelleting container with a rejection signal. This invention solves the problems of existing pellet counters where the feed gate response speed needs improvement, the feed gate extension speed cannot be monitored, and there is no feedback on whether there is jamming, which can easily cause pellet damage and affect the accuracy of pellet counting.

Description

Technical Field

[0001] This invention relates to the field of material gate control technology, and in particular to a method for preventing jamming of the material gate of a pellet counter and the pellet counter itself. Background Technology

[0002] Currently, a common method for controlling a counting machine's gate is to use a solenoid valve to control a cylinder, which extends the gate to close it and retracts it to open it. The gate's extension speed is controlled by adjusting the air pressure. However, the distance from which the pills fall to the gate is short, allowing for a short reaction time. Delayed response can easily affect counting accuracy or cause pill jamming. Furthermore, the solenoid valve-controlled cylinder method cannot monitor the gate's extension speed, its reaction speed needs improvement, and it cannot provide feedback on whether pill jamming has occurred. When jamming occurs, it cannot protect the pills, causing them to be damaged. It also cannot provide a signal for rejection, affecting counting accuracy. Existing technologies, such as the fully visualized gate structure of a counting machine (application number 201821682031.X), can detect pill jamming in a timely manner, but pills can still be damaged. It cannot monitor the gate's extension speed, requires human visual monitoring which is not very accurate, or requires additional visual monitoring equipment to monitor jamming, increasing costs. Summary of the Invention

[0003] (a) Technical problems to be solved

[0004] To address the aforementioned problems, this invention provides a method for preventing jamming at the feed gate of a pellet counter and a pellet counter in general. This solves the problems of existing pellet counters where the feed gate response speed needs to be improved, the feed gate extension speed cannot be monitored, the feed gate cannot provide feedback on whether the feed is jammed, and the pellets are easily damaged when the feed is jammed, which also affects the accuracy of the pellet count.

[0005] (II) Technical Solution

[0006] To address the aforementioned technical problems, this invention provides a method for preventing jamming at the feed gate of a pellet counter. The feed gate is connected to the extended end of the mover of a corresponding linear motor, and the servo driver of the linear motor is connected to a controller. The method for preventing jamming at the feed gate of a pellet counter includes the following steps:

[0007] S1, Count the number of particles that pass through each feed gate;

[0008] S2. When the number of particles reaches the set value, the material gate is extended by controlling the corresponding linear motor to block the falling particles.

[0009] S3. While the linear motor controls the material gate to extend, the real-time torque value of the linear motor is monitored. When the real-time torque value is greater than or equal to the jamming torque setting value and the duration is greater than the time setting value, proceed to the next step.

[0010] S4. Immediately control the material gate to retract via the corresponding linear motor, and mark the current granulation container and the next granulation container with rejection signals.

[0011] Furthermore, step S3 includes:

[0012] S3.1 While the linear motor controls the material gate to extend, the real-time torque value of the linear motor is monitored;

[0013] S3.2 Determine whether the real-time torque value is greater than or equal to the jamming torque setting value. If yes, start timing for the duration during which the real-time torque value is greater than or equal to the jamming torque setting value, and proceed to step S3.3; otherwise, return to step S3.1 to continue monitoring.

[0014] S3.3 Determine whether the duration for which the real-time torque value is greater than or equal to the material clamping torque setting value is greater than the time setting value. If yes, proceed to step S4; otherwise, return to step S3.1 to continue monitoring.

[0015] Furthermore, the number of material gates is greater than 1, and each material gate corresponds to one linear motor.

[0016] Furthermore, the controller independently controls the servo driver of the linear motor corresponding to each material gate based on the EtherCat bus.

[0017] Furthermore, in step S1, the material particles passing through each feed gate are captured by several photoelectric sensors.

[0018] Furthermore, in step S1, the number of particles in each feed gate is obtained by counting using a microcontroller's particle counting plate.

[0019] Furthermore, in step S3, the torque setting value of the clamping device is 1.5 times the rated torque, and the time setting value should be at least 10ms.

[0020] Furthermore, in step S4, the material gate retracts by a distance not greater than 2mm.

[0021] Furthermore, the granules are pharmaceutical granules.

[0022] This invention also discloses a counting machine, including a controller, a linear motor, and a feed gate. The controller operates the feed gate anti-jamming control method to control the extension and retraction of the linear motor. The feed gate is connected to the moving end of the corresponding linear motor.

[0023] (III) Beneficial Effects

[0024] The above technical solution of the present invention has the following advantages:

[0025] (1) The linear motor corresponding to the material gate of the present invention is independently controlled by the controller based on the EtherCat bus. It can monitor the real-time torque value, speed and time of the linear motor when the material gate extends. It has good feedback. It determines the material gate jamming based on the dual judgment of the real-time torque value being too large and the duration of the real-time torque value being too large, thereby improving the accuracy of the jamming judgment and reducing the misjudgment caused by the instantaneous torque value being too large. Moreover, it quickly retracts when the jamming is determined to prevent the medicine from being damaged and protect the medicine. At the same time, it gives a rejection signal for rejection, ensuring the accuracy of counting the medicine.

[0026] (2) The EtherCat bus control used in this invention has a fast response speed, which is conducive to the rapid extension of the material gate and reduces material jamming. Even if material jamming occurs, it is conducive to a rapid retraction response when material jamming occurs, thereby improving the speed and stability of the equipment. Attached Figure Description

[0027] The features and advantages of the invention will be more clearly understood by referring to the accompanying drawings, which are schematic and should not be construed as limiting the invention in any way. In the drawings:

[0028] Figure 1 This is a schematic diagram of the counting machine's feed door being opened according to an embodiment of the present invention;

[0029] Figure 2 This is a schematic diagram of the counting machine's feed door being closed according to an embodiment of the present invention;

[0030] Figure 3 This is a flowchart of the anti-jamming control method for the material gate of the pellet counting machine according to an embodiment of the present invention;

[0031] Figure 4 This is a schematic diagram of the retraction procedure of the feed gate of the pellet counting machine according to an embodiment of the present invention;

[0032] Figure 5 The encoder value curve of the linear motor corresponding to the material gate of the pellet counting machine in an embodiment of the present invention;

[0033] Figure 6 This is an enlarged view of the material encoder value of the linear motor corresponding to the material gate of the pellet counting machine in an embodiment of the present invention;

[0034] In the diagram: 1: feed gate; 2: linear motor. Detailed Implementation

[0035] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0036] The present invention addresses the particle counting machine material gate 1 as described in the embodiments of the present invention. Figure 1-2 As shown, the material gate 1 is connected to the extended end of the mover of the corresponding linear motor 2, and the material gate 1 is a baffle plate. Figure 1This indicates the state where linear motor 2 controls material gate 1 to retract and material gate 1 to open. Figure 2 This indicates the situation where the linear motor 2 controls the material gate 1 to extend and the material gate 1 to close. The linear motor 2 is controlled by a connected controller. The controller, through the linear motor 2, controls the material gate 1 and can monitor or provide feedback on the torque value, speed, and time when the linear motor 2 controls the material gate 1 to extend. The response speed is fast, but jamming may still occur when the granules fall too fast or are too long.

[0037] This invention provides a method for preventing jamming at the material gate of a grain counting machine. Figure 3 As shown, in this embodiment, the material particles are pharmaceutical particles, and the process includes the following steps:

[0038] S1, count the number of particles that pass through each feed gate 1;

[0039] The integrated high-speed photoelectric sensor captures the pills vibrating and falling from the vibrating plate of the pill counter into the corresponding feed gate 1, and the number of pills in each feed gate 1 is obtained by counting with a single-chip microcomputer counting board.

[0040] S2. When the number of particles reaches the set particle size, the controller controls the material gate 1 to extend via the servo driver of the corresponding linear motor 2, as follows: Figure 2 As shown, it prevents the material particles from falling;

[0041] Determine whether the number of pills in each feed gate 1 has reached the set value. If so, control the feed gate 1 to extend through the corresponding linear motor 2 to prevent the pills from falling and being bottled; otherwise, continue counting.

[0042] The number of material gates 1 is greater than 1, and each material gate 1 corresponds to one linear motor 2. In this embodiment, each vibratory plate has 8 tracks, each track has at least 1 material gate 1, and there is also a total material gate 1. The counting machine has at least 9 material gates 1. The linear motor 2 performs magnetic pole calibration before being powered on, and then returns to the running origin.

[0043] The distance from which the medicine falls to the motor baffle of feed gate 1 is short, so the entire control system needs to react quickly. The controller, based on an EtherCat bus, independently controls the servo driver of the linear motor 2 corresponding to each feed gate 1, with a response speed within 1ms. It is fast and can provide feedback on the torque value, time, and speed of the linear motor 2 when controlling the feed gate 1 to extend, enabling real-time monitoring and effectively reducing material jamming. However, when the medicine falls too fast or is too long, material jamming may still occur, requiring subsequent steps to address the jamming situation.

[0044] S3. While the linear motor 2 controls the material gate 1 to extend, the controller monitors the real-time torque value of the linear motor 2. When the real-time torque value is greater than or equal to the jamming torque setting value, and the duration is greater than the time setting value, proceed to the next step; specifically including:

[0045] S3.1 While the linear motor 2 controls the material gate 1 to extend, the real-time torque value of the linear motor 2 is monitored.

[0046] The study found that when the feed gate 1 extends and jams the medicine pellets, the torque value of the linear motor 2 is too large. Therefore, the controller can monitor whether the torque value of each linear motor 2 is greater than the jamming torque setting value to determine whether a jam has occurred.

[0047] S3.2 Determine whether the real-time torque value is greater than or equal to the jamming torque setting value. If yes, start timing for the duration during which the real-time torque value is greater than or equal to the jamming torque setting value, and proceed to step S3.3; otherwise, return to step S3.1 to continue monitoring.

[0048] The material clamping torque setting is 1.5 times the rated torque. During the extension of the material gate 1, the torque value of the linear motor 2 may momentarily exceed the set value. Moreover, due to the friction between the extension structure of the material gate 1 and the device, especially the increased friction caused by falling powder, the torque value of the linear motor 2 may also momentarily exceed the set value. Therefore, when the real-time torque value is greater than or equal to the material clamping torque setting value, it is necessary to time the duration for which the real-time torque value is greater than or equal to the material clamping torque setting value to eliminate the situation of momentary torque exceeding the set value and avoid misjudgment.

[0049] S3.3 Determine whether the duration for which the real-time torque value is greater than or equal to the material clamping torque setting value is greater than the time setting value. If yes, proceed to step S4; otherwise, return to step S3.1 to continue monitoring.

[0050] The time setting should be at least 10ms and should be manually set. The accuracy of jam monitoring is improved by judging both the magnitude of the real-time torque value and the duration of an excessively high real-time torque value.

[0051] S4. The controller immediately controls the material gate 1 to retract via the corresponding linear motor 2, and marks the current granulation container and the next granulation container with rejection signals.

[0052] When a jam is confirmed, the controller instantly controls the corresponding linear motor 2 via its servo driver, applying a reaction force to cause the feed gate 1 to retract a certain distance, not exceeding 2mm, thereby effectively protecting the granules. The feed gate 1 corresponding to the linear motor 2's jam retraction procedure is as follows: Figure 4 As shown, the encoder value curve of the linear motor corresponding to the feed gate of the pellet counting machine is as follows: Figure 5As shown, the encoder value of the linear motor corresponding to the feed gate of the pellet mill is amplified when the feed is jammed. Figure 6 middle.

[0053] After the material jams, the feed gate 1 retracts, and the granules fall into the hopper. This causes the current vial, which has already reached its set granule count, to have one more granule, while the next vial will have one less, affecting the granule count in both vials. Therefore, a rejection signal is marked on both the current and next granulation containers for rejection at the rejection station. Figure 1 As shown.

[0054] In summary, the above-described method for preventing jamming at the feed gate of a pellet counter and the pellet counter itself offer the following advantages:

[0055] (1) The linear motor corresponding to the material gate of the present invention is independently controlled by the controller based on the EtherCat bus. It can monitor the real-time torque value, speed and time of the linear motor when the material gate extends. It has good feedback. It determines the material gate jamming based on the dual judgment of the real-time torque value being too large and the duration of the real-time torque value being too large, thereby improving the accuracy of the jamming judgment and reducing the misjudgment caused by the instantaneous torque value being too large. Moreover, it quickly retracts when the jamming is determined to prevent the medicine from being damaged and protect the medicine. At the same time, it gives a rejection signal for rejection, ensuring the accuracy of counting the medicine.

[0056] (2) The EtherCat bus control used in this invention has a fast response speed, which is conducive to the rapid extension of the material gate and reduces material jamming. Even if material jamming occurs, it is conducive to a rapid retraction response when material jamming occurs, thereby improving the speed and stability of the equipment.

[0057] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit it; although the embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A method for preventing jamming at the material gate of a grain counting machine, characterized in that, The feed gate is connected to the extended end of the corresponding linear motor, and the servo driver of the linear motor is connected to the controller. The anti-jamming control method for the feed gate of the counting machine includes the following steps: S1, Count the number of particles that pass through each feed gate; S2. When the number of particles reaches the set value, the material gate is extended by controlling the corresponding linear motor to block the falling particles. S3. While the linear motor controls the material gate to extend, the real-time torque value of the linear motor is monitored. When the real-time torque value is greater than or equal to the jamming torque setting value, and the duration is greater than the time setting value, proceed to the next step; Step S3 includes: S3.1 While the linear motor controls the material gate to extend, the real-time torque value of the linear motor is monitored; S3.2 Determine whether the real-time torque value is greater than or equal to the jamming torque setting value. If yes, start timing for the duration during which the real-time torque value is greater than or equal to the jamming torque setting value, and proceed to step S3.3; otherwise, return to step S3.1 to continue monitoring. S3.3 Determine whether the duration for which the real-time torque value is greater than or equal to the material clamping torque setting value is greater than the time setting value. If yes, proceed to step S4; otherwise, return to step S3.1 to continue monitoring. S4. Immediately control the material gate to retract via the corresponding linear motor, and mark the current granulation container and the next granulation container with rejection signals.

2. The anti-jamming control method for the material gate of a grain counting machine according to claim 1, characterized in that, The number of material gates is greater than 1, and each material gate corresponds to one linear motor.

3. The anti-jamming control method for the material gate of a grain counting machine according to claim 2, characterized in that, The controller independently controls the servo driver of the linear motor corresponding to each material gate based on the EtherCat bus.

4. The anti-jamming control method for the material gate of a pellet counting machine according to claim 1, characterized in that, In step S1, the material particles passing through each material gate are captured by several photoelectric sensors.

5. The anti-jamming control method for the material gate of a pellet counting machine according to claim 1, characterized in that, In step S1, the number of particles in each feed gate is obtained by counting using a microcontroller's particle counting plate.

6. The anti-jamming control method for the material gate of a pellet counting machine according to claim 1, characterized in that, In step S3, the clamping torque setting value is 1.5 times the rated torque, and the time setting value is at least 10ms.

7. The anti-jamming control method for the material gate of a pellet counting machine according to claim 1, characterized in that, In step S4, the material gate retracts no more than 2mm.

8. The anti-jamming control method for the material gate of a pellet counting machine according to claim 2, characterized in that, The granules are pharmaceutical granules.

9. A grain counting machine, characterized in that, The device includes a controller, a linear motor, and a feed gate. The controller operates according to the anti-jamming control method for the feed gate of a counting machine as described in any one of claims 1-8 to control the extension and retraction of the linear motor. The feed gate is connected to the extended end of the corresponding linear motor's mover.

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