A bag-out detection system and method for a garbage baler

Abstract

The present invention discloses a system and method for detecting the release of garbage balers. The detection system includes: a distribution box internally equipped with a microcontroller and a distance sensor connected to the microcontroller, a door opening / closing signal detection device, and a network transmission module, all of which are connected to a power module; the microcontroller is connected to a monitoring host computer via the network transmission module, which transmits data to the monitoring host computer in a timely and reliable manner, and the monitoring host computer calculates the number of bags released by the garbage baler; the door opening / closing signal detection device is used to collect the door opening and closing signals of the garbage baler, and the door opening / closing signal detection device includes an optocoupler relay, the input end of the optocoupler relay is connected to the PLC control system of the garbage baler's door, and the output end is connected to the door opening / closing signal detection end of the microcontroller via a contact switch; the distance sensor is used to detect the release of bags from the garbage baler. The present invention has a simple structure and is easy to operate, and can be widely used in intelligent processing of garbage baling.

Description

Technical Field

[0001] The present invention relates to the field of monitoring and detection machinery, and in particular to a bag-out detection system and method for a garbage baler. Background Art

[0002] With the rapid development of technology and the continuous expansion of application fields, garbage recycling manufacturers have higher and higher requirements for garbage packaging and more and more intelligent demands. Under this circumstance, the situation where the number of packages packed by traditional garbage balers needs to be manually recorded and then manually imported into inventory every day has become increasingly unable to meet the requirements, because manual records are prone to omissions and errors, which interferes with inventory management.

[0003] Chinese invention patent publication number CN112810878A discloses a device for counting and packaging vegetables. The device comprises a housing and a control box. The housing has a door in the middle of the left front of the housing, hinged on both ends. A control box is located on the right side of the door. A display is embedded in the front of the control box, with a control switch located below the display. A controller is screwed to the top of the control box, and a storage device is located below the controller, secured to the inner wall of the control box with screws. A network interface is located to the right of the storage device, secured to the inner wall of the control box with screws. A conveyor belt a is located at the left end of the housing, with the right end of the conveyor belt a located within the housing. Conveyor belt a is provided with four drive shafts arranged evenly from left to right, each of which is mounted on a support shaft via bearings. A motor is located within the motor box, with the motor shaft passing through the motor box and meshing with the drive shafts via gears. The device is characterized by ease of operation, automatic counting of packages, and quality inspection of vegetables. This technical solution utilizes a high-low coordination of the conveyor belt and the packaging machine to complete the entire inspection and packaging process. This complex structure, limited by equipment manufacturing and site availability, results in high operating costs.

[0004] In summary, there is an urgent need for a bag-out detection system with a simple structure that matches existing garbage baling machines. Summary of the Invention

[0005] At present, the number of packages packed by traditional garbage balers needs to be recorded manually and then manually imported into the inventory system every day, which cannot meet the needs of intelligence.

[0006] In order to solve the above technical problems, the present application provides, on the one hand, a bag output detection system for a garbage baler, which is connected to the garbage baler and includes: a distribution box, which is internally provided with a microcontroller and a distance sensor, a door opening and closing signal detection device and a network transmission module connected to the microcontroller, and the microcontroller, the distance sensor, the door opening and closing signal detection device and the network transmission module are all connected to the power module; a monitoring host computer, the microcontroller is connected to the monitoring host computer via the network transmission module, the network transmission module sends data to the monitoring host computer in a timely and reliable manner, and the calculation program of the monitoring host computer calculates the number of bags output by the garbage baler based on the received data signal; wherein, the door opening and closing signal detection device is used to collect the door opening signal and door closing signal of the garbage baler, and the door opening and closing signal detection device includes an optocoupler relay, the input end signal of the optocoupler relay is connected to the machine door PLC control system of the garbage baler, and the output end is connected to the door opening and closing signal detection end of the microcontroller via a contact switch; the distance sensor is used to realize the detection of the bag output of the garbage baler.

[0007] According to an embodiment of the present application, the optocoupler relay includes a photodiode opto-isolator, a closed optical channel and a photoelectric sensor. The photodiode opto-isolator converts the electrical signal at the input end into an optical signal. The photoelectric sensor detects the optical signal through the closed optical channel and converts it into electrical energy or modulates the current flowing out of an external power supply. The electrical energy or current signal is sent to the microcontroller.

[0008] According to an embodiment of the present application, the microcontroller specifically includes a capture module, a control module and a judgment module: the capture module is used to capture the door opening signal and door closing signal of the garbage baler, and when the door opening signal and the door closing signal are captured, the effectiveness of the garbage packaging process is judged by the interval time between the two; when the interval time reaches the preset time, it is judged to be valid; the control module is used to control the microcontroller to send a packaging signal to the monitoring host computer when the packaging process is valid and the door opening signal and the door closing signal are captured; the judgment module is used to verify the effective value of the distance sensor, and when it is judged that the distance value detected by the distance sensor is within the preset range, the control microcontroller sends a packet signal to the monitoring host computer.

[0009] According to an embodiment of the present application, the packet outgoing detection system further includes a storage module for recording detailed information of signals uploaded by the distance sensor and the door opening and closing signal detection device.

[0010] According to an embodiment of the present application, a laser sensor is used as the distance sensor.

[0011] According to an embodiment of the present application, a control switch is provided on the side of the distribution box, and the control switch is connected to the power module. The power module provides power to the packet detection system after the action of the power filter.

[0012] According to an embodiment of the present application, the distance sensor is connected to the microcontroller using the RS485 communication method, and the network transmission module is connected to the microcontroller using the RS232 communication method.

[0013] Another aspect of the present application provides a method for detecting a package out of a garbage baler, which uses the above-mentioned system for detecting a package out of a garbage baler, and includes the following steps:

[0014] Collect the door opening signal, door closing signal of the garbage baler and the distance signal transmitted by the distance sensor;

[0015] The validity of the packing process is judged according to the time interval between adjacent door opening signals and door closing signals. When the packing process is judged to be valid, the microcontroller sends a packing signal to the monitoring host computer;

[0016] Verify the distance value measured by the distance sensor. When the verified distance value is within the preset range, the microcontroller transmits a packet signal to the monitoring host computer;

[0017] The monitoring host computer calculates the specific number of packets based on the received signal.

[0018] According to an embodiment of the present application, the method includes recording and storing detailed information of the transmission signal in a storage module.

[0019] According to an embodiment of the present application, the information recorded in the storage module is encrypted and reported to the monitoring host computer.

[0020] The technical solution of the present invention has the following beneficial effects compared with the prior art:

[0021] 1. This application mainly uses intelligent monitoring to collect multiple signals and relies on calculation programs to achieve accurate counting of the number of bags output by the garbage baler and put into storage, reducing the output of labor costs, eliminating system statistical errors caused by human factors, and thus improving the accuracy of the data in the factory's inventory management system.

[0022] 2. This application uses a controller for overall control, which is convenient for operation. The distance sensor mainly exchanges data with the microcontroller through the 485 bus. The 485 bus has the characteristics of long transmission distance and strong anti-interference ability, which facilitates flexible wiring on site.

[0023] 3. This system uses AC input. The power filter can effectively reduce the interference of the packaging equipment on the switching power supply at the moment of starting and stopping. Then, the AC power is stably supplied to the switching power supply, thereby realizing the conversion of AC power to system power supply voltage, providing the system with stable power supply for signal acquisition and information processing.

[0024] 4. The acquisition of door opening / closing signals mainly adopts relays and optocoupler isolation. Because the packaging equipment is controlled by PLC, it mostly uses AC intermediate relays, which will cause certain interference to the stability of the system at the moment of action. The use of relays and optocoupler isolation can not only realize the function but also avoid the detection system from causing irreparable damage to the packaging machine's own control system, thereby playing a protective role. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 A schematic structural diagram of a bag-out detection system for a garbage baler provided as an example of the present invention;

[0026] Figure 2 A flowchart of a method for detecting a package output of a garbage packing machine provided as an example of the present invention. DETAILED DESCRIPTION

[0027] The present invention will be further described below in conjunction with the accompanying drawings and specific examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0028] The signal and power lines of electronic products can be subject to voltage surges caused by lightning, electrostatic discharge, radio frequency transmissions, switching pulses, and power supply disturbances. The primary function of an optoisolator is to block these high voltages and voltage transients, preventing surges in one part of the system from interfering with or damaging other parts. An optocoupled solid-state relay contains a photodiode optoisolator that drives a power switch, typically a pair of complementary MOSFETs. Normal digital signals are smoothly coupled and transmitted to the other side via the optocoupler, while any interfering noise signals on the input side are prevented from passing through the optocoupler to the output.

[0029] See also Figure 1 、 Figure 2 According to the working principle of the garbage baler, this application proposes a bag-out detection system and method for the garbage baler. The bag-out detection system uses a multi-channel monitoring method to control the entire working state to achieve the most accurate monitoring effect.

[0030] A bag-out detection system for a garbage baler is connected to the garbage baler and includes a distribution box and a monitoring host computer in communication with the distribution box. The distribution box integrates a microcontroller, a distance sensor, a door opening and closing signal detection device, and a network transmission module.

[0031] A microcontroller and a distance sensor, a door opening and closing signal detection device and a network transmission module connected to the microcontroller are provided inside the distribution box. The microcontroller, the distance sensor, the door opening and closing signal detection device and the network transmission module are all connected to the power module.

[0032] The microcontroller is used to determine the effectiveness of the garbage baling machine's packaging process, and if it is determined to be effective, the signal is transmitted to the monitoring host computer via the network transmission module; the microcontroller is also used to verify whether the distance value transmitted by the distance sensor is within a preset range. When the distance value is verified to be within the preset range, it is determined to be effective and the signal is transmitted to the monitoring host computer via the network transmission module.

[0033] Monitoring host computer, the microcontroller is connected to the monitoring host computer via the network transmission module, the network transmission module sends the data to the monitoring host computer in a timely and reliable manner, and the calculation program installed in the monitoring host computer calculates these data to complete the detection and counting function.

[0034] The door opening and closing signal detection device is used to collect the door opening and closing signals of the garbage baler. The door opening and closing signal detection device includes an optocoupler relay. The input signal of the optocoupler relay is connected to the PLC control system of the garbage baler's door, and the output signal is connected to the door opening and closing signal detection end of the microcontroller through a contact switch.

[0035] The distance sensor is used to detect the distance at which the garbage baler discharges the bags.

[0036] In this embodiment, the network transmission module is a data transmission device that fully supports the 4G / 3G / 2G communication networks of China Mobile, China Unicom and China Telecom, and realizes two-way, transparent, wireless transmission between serial devices and servers, and between serial devices. The Internet of Things 4G module has the characteristics of simple use, USB / Bluetooth parameter setting, and remote maintenance.

[0037] Furthermore, the network transmission module supports simultaneous multi-device communication. RS485 and RS232 can connect a single device simultaneously, while RJ45 can connect multiple devices simultaneously. For example, RS485 can be used to connect to a distance sensor, while RS232 can be used to connect to a microcontroller.

[0038] Among them, the microcontroller specifically includes a capture module, a control module and a judgment module;

[0039] The capture module is used to capture the door opening and closing signals of the garbage packing machine. When the door opening and closing signals are captured, the validity of the garbage packing process is judged by the interval time between the two. When the interval time reaches the preset time, it is judged to be valid;

[0040] The control module is used to control the microcontroller to send a packaging signal to the monitoring host computer when the packaging process is valid and the door opening signal and door closing signal are captured;

[0041] The judgment module is used to verify the effective value of the distance sensor. When it is judged that the distance value detected by the distance sensor is within a preset range, the microcontroller is controlled to send a packet signal to the monitoring host computer.

[0042] In this embodiment, it takes 30 minutes for the garbage baler to perform a normal baling. The door opening and closing signal detection device is used to collect the door closing signal and door opening signal of the garbage baler. The door closing signal represents the initial identification of a baling signal, and the door opening signal represents the termination signal of the baling process. The microcontroller is connected to the door opening and closing signal detection device. According to the time interval between the door closing signal and the door opening signal, if it meets 30 minutes, it is judged as a valid baling process and a baling signal is uploaded. If it is not 30 minutes, it is judged to be invalid and the baling signal is not uploaded.

[0043] In this embodiment, the distance sensor is used to feedback the distance value between it and the target package to the microcontroller. When the distance value is less than 1 meter, it means that a package has been output. The microcontroller determines that the package is valid and uploads a package output signal once; when the distance value is greater than 1 meter, the microcontroller determines that the package is invalid and does not upload a signal.

[0044] Furthermore, the distribution box of this embodiment also includes a storage module, which is connected to the door opening and closing signal detection device and the counting module, and is used to record detailed information uploaded by the distance sensor, the door opening and closing signal detection device, and the counting module. Specifically, this embodiment uses a microcontroller to control the storage module to store packaged information. This embodiment can adopt block storage, with each block storing counting data for a period of time.

[0045] Furthermore, the stored data may also include production details data, including detailed information such as packaging date, packaging time, number of packages, etc., and submitted for storage in the memory card for easy export at any time.

[0046] In this embodiment, the device for detecting the door opening and closing signal of a garbage baler utilizes an optocoupler relay, a combination of an isolation relay and an optocoupler, to reduce interference between systems and ensure signal integrity. The optocoupler relay comprises a photodiode optoisolator, a closed optical channel, and a photoelectric sensor. The photodiode optoisolator converts the electrical signal at its input end into an optical signal. The optical signal, detected by the photoelectric sensor through the closed optical channel, is converted into electrical energy or modulated into a current flowing from an external power supply. The electrical energy or current signal is then transmitted to a microcontroller.

[0047] Furthermore, the distance sensor in this embodiment utilizes a laser sensor. Due to the laser's excellent monochromaticity and strong directionality, coupled with its integrated semiconductor electronic circuitry, laser sensors can operate day and night, improve distance measurement accuracy, and significantly reduce weight and power consumption compared to photoelectric rangefinders.

[0048] In this embodiment, a control switch is provided on the side of the distribution box, and the control switch is connected to the power module. The power module provides power to the packet detection system after the power filter.

[0049] like Figure 2 As shown, the present application also discloses a method for detecting a package out of a garbage baler, which uses the above-mentioned system for detecting a package out of a garbage baler. The method includes the following steps:

[0050] Collect the door opening signal, door closing signal of the garbage baler and the distance signal transmitted by the distance sensor;

[0051] The validity of the packing process is judged according to the time interval between adjacent door opening signals and door closing signals. When the packing process is judged to be valid, the microcontroller sends a packing signal to the monitoring host computer;

[0052] Verify the distance value measured by the distance sensor. When the verified distance value is within the preset range, the microcontroller transmits a packet signal to the monitoring host computer;

[0053] The monitoring host computer calculates the specific number of packets based on the received signal.

[0054] Furthermore, the method further includes recording and storing detailed information of the transmission signal in a storage module.

[0055] Furthermore, the method can also encrypt the information recorded in the storage module and report it to the monitoring host computer.

[0056] The working principle of the detection system of this application:

[0057] The present invention provides a bag-out detection system for a garbage baler. A control switch is connected to a power supply through a cable. When the control switch is turned on, power is supplied to the system. A door-opening and door-opening signal detection device detects the door-opening and door-opening signal of the garbage baler and transmits the detected information to a microcontroller. The door of the garbage baler closes to baling the garbage. After baling is completed, the garbage baler opens the door to baling the garbage. The microcontroller transmits a baling signal to a monitoring host computer. A conveyor belt transports the baled garbage. During the transportation, a distance sensor detects the distance between the conveyor belt and the baled garbage and transmits the value to the microcontroller. The microcontroller determines whether the distance is within a preset range based on the value transmitted by the distance sensor, and further determines whether the baling process is valid. If it is determined to be valid, a bag-out signal is sent to the monitoring host computer. The microcontroller transmits the signal to the monitoring host computer through a network. The monitoring host computer calculates the signal information according to a set calculation program. The staff can check the baling quantity and whether there is any problem on the monitoring host computer. After the garbage baler has finished working, the control switch is turned off.

[0058] This embodiment collects different signals to provide real and effective data for the CPU to perform logical judgment, thereby enabling real-time and accurate acquisition of the production data of the garbage packing machine and preventing confusion in inventory records.

[0059] In summary, this application has the following beneficial effects:

[0060] 1. This application mainly uses intelligent monitoring to collect multiple signals and relies on calculation programs to achieve accurate counting of the number of bags output by the garbage baler and put into storage, reducing the output of labor costs, eliminating system statistical errors caused by human factors, and thus improving the accuracy of the data in the factory's inventory management system.

[0061] 2. This application uses a controller for overall control, which is convenient for operation. The distance sensor mainly exchanges data with the microcontroller through the 485 bus. The 485 bus has the characteristics of long transmission distance and strong anti-interference ability, which facilitates flexible wiring on site.

[0062] 3. This system uses AC input. The power filter can effectively reduce the interference of the packaging equipment on the switching power supply at the moment of starting and stopping. Then, the AC power is stably supplied to the switching power supply, thereby realizing the conversion of AC power to system power supply voltage, providing the system with stable power supply for signal acquisition and information processing.

[0063] 4. The acquisition of door opening / closing signals mainly adopts relays and optocoupler isolation. Because the packaging equipment is controlled by PLC, it mostly uses AC intermediate relays, which will cause certain interference to the stability of the system at the moment of action. The use of relays and optocoupler isolation can not only realize the function but also avoid the detection system from causing irreparable damage to the packaging machine's own control system, thereby playing a protective role.

[0064] The above are only preferred embodiments of the present invention and do not limit the implementation mode and protection scope of the present invention. For those skilled in the art, it should be aware that all solutions obtained by equivalent substitutions and obvious changes made using the description and illustrations of the present invention should be included in the protection scope of the present invention.

Claims

1. A bag-out detection system for a garbage baler, connected to the garbage baler, characterized in that: include: A distribution box is provided with a microcontroller and a distance sensor, a door opening and closing signal detection device and a network transmission module connected to the microcontroller, and the microcontroller, the distance sensor, the door opening and closing signal detection device and the network transmission module are all connected to the power module; A monitoring host computer, wherein the microcontroller is connected to the monitoring host computer via the network transmission module, the network transmission module sends data to the monitoring host computer in a timely and reliable manner, and a calculation program of the monitoring host computer calculates the number of packages output by the garbage packing machine according to the received data signal; The door opening and closing signal detection device is used to collect the door opening and closing signals of the garbage baler. The door opening and closing signal detection device includes an optocoupler relay. The input end signal of the optocoupler relay is connected to the machine door PLC control system of the garbage baler, and the output end is connected to the door opening and closing signal detection end of the microcontroller via a contact switch. Wherein, the distance sensor is used to detect the discharge of the garbage packing machine; The optical coupler relay includes a photodiode optical isolator, a closed optical channel, and a photoelectric sensor. The photodiode optical isolator converts the electrical signal at the input end into an optical signal. The photoelectric sensor detects the optical signal through the closed optical channel and converts it into electrical energy or modulates the current flowing from the external power supply. The electrical energy or current signal is sent to the microcontroller. The microcontroller specifically includes a capture module, a control module and a judgment module: The capture module is used to capture the door opening signal and door closing signal of the garbage packing machine, and when the door opening signal and the door closing signal are captured, the validity of the garbage packing process is judged by the interval time between the two; when the interval time reaches a preset time, it is judged to be valid; The control module is used to control the microcontroller to send a packaging signal to the monitoring host computer when the packaging process is valid and the door opening signal and the door closing signal are captured; The judgment module is used to verify the effective value of the distance sensor, and when it is determined that the distance value detected by the distance sensor is within a preset range, control the microcontroller to send a packet signal to the monitoring host computer.

2. A bag-out detection system for a garbage baler according to claim 1, characterized in that: The packet outgoing detection system further includes a storage module for recording detailed information of the signals uploaded by the distance sensor and the door opening and closing signal detection device.

3. The bag-out detection system for a garbage packing machine according to claim 1, characterized in that: The distance sensor adopts a laser sensor.

4. The bag-out detection system for a garbage packing machine according to claim 1, characterized in that: A control switch is provided on the side of the distribution box, and the control switch is connected to the power module. The power module provides power to the packet outgoing detection system after the action of the power filter.

5. The bag-out detection system for a garbage baler according to claim 1, characterized in that: The distance sensor is connected to the microcontroller using the RS485 communication mode, and the network transmission module is connected to the microcontroller using the RS232 communication mode.

6. A method for detecting a package out of a garbage baler, using the package out of a garbage baler detection system according to any one of claims 1 to 5, characterized in that: The following steps are involved: Collect the door opening signal, door closing signal of the garbage baler and the distance signal transmitted by the distance sensor; The validity of the packing process is judged according to the time interval between adjacent door opening signals and door closing signals. When the packing process is judged to be valid, the microcontroller sends a packing signal to the monitoring host computer; Verify the distance value measured by the distance sensor. When the verified distance value is within the preset range, the microcontroller transmits a packet signal to the monitoring host computer; The monitoring host computer calculates the specific number of packets based on the received signal.

7. A method for detecting a bag out of a garbage packing machine according to claim 6, characterized in that: The method also includes recording and storing detailed information of the transmission signal in a storage module.

8. A method for detecting a bag out of a garbage packing machine according to claim 7, characterized in that: The information recorded in the storage module is encrypted and reported to the monitoring host computer.

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