A brake disc stacking line and stacking method

Abstract

This invention relates to a brake disc palletizing line and method, belonging to the field of conveyor packaging technology. The brake disc palletizing line includes a conveyor belt, a first camera device and an encoder, and at least one palletizing system located around the conveyor belt. The palletizing system includes a second camera device, a drop-off robot, a transfer table, and a palletizing robot. The brake disc palletizing method is as follows: the first camera device photographs and identifies the target product on the conveyor belt, and the encoder tracks it; the drop-off robot picks up the target product from the conveyor belt and moves it to the second camera device for photographing, and the photographic information is transmitted to the control system; the control system calculates the model of the target product and the deviation data between the center point of the target product and the center point of the transfer table; the drop-off robot adjusts the placement position of the target product on the transfer table according to the instructions of the control system and places the target product on the transfer table; the palletizing robot accurately picks up the target product from the transfer table and places it on a pallet.

Description

Technical Field

[0001] This invention relates to a brake disc palletizing line and palletizing method, belonging to the field of conveyor packaging technology. Background Technology

[0002] Brake discs are a key component for automobile braking. During the production process, brake discs are stacked together for storage, which saves storage space.

[0003] Due to the large variety of brake disc models, brake discs are currently generally unloaded and stacked manually. Since brake discs are cast iron parts, each brake disc weighs at least 5 kilograms, and the daily output is approximately 20,000 pieces or more. Manual stacking is extremely labor-intensive and inefficient. Furthermore, since brake discs are cast, manual unloading requires wearing high-temperature resistant gloves. In addition, brake discs have irregular shapes, with raised mounting outer circles on the upper disc. When stacking manually, the position of each piece will be off, making it difficult to ensure the compactness and stability of the stack. This can easily cause the discs to scatter during transportation.

[0004] Therefore, a brake disc stacking line and stacking method are needed to replace the existing manual stacking method. Summary of the Invention

[0005] The purpose of this invention is to provide a new technical solution to improve or solve the technical problems existing in the prior art as described above.

[0006] The technical solution provided by this invention is as follows: a brake disc palletizing line, including a conveyor belt, a first camera device and an encoder, and at least one palletizing system disposed around the conveyor belt. The palletizing system includes a second camera device, a loading robot, a transfer station and a palletizing robot. The loading robot and the palletizing robot are respectively disposed on both sides of the conveyor belt. The transfer station is located between the conveyor belt and the palletizing robot. The system also includes a control system. The control system, the first camera device, the encoder, the second camera device, the loading robot and the palletizing robot are communicatively connected.

[0007] Compared with the prior art, the technical solution provided by the present invention has the following beneficial effects: the brake disc stacking line and stacking method of the present invention can replace manual unloading and stacking. During stacking, the target products are stacked alternately on the convex and concave surfaces of the pallet. Not only can the upper and lower brake discs make use of each other's space and the stacking is compact, but the robot arm also works by the set method, and the working stability is high.

[0008] Based on the above technical solution, the present invention can be further improved as follows.

[0009] Furthermore, the first camera device and the second camera device are 3D cameras or 2D cameras; the first camera device is used to identify the initial coordinate position of the brake disc, and the second camera device is used to identify the positional deviation of the brake disc.

[0010] Furthermore, a set of unloading robots in the palletizing system includes a first unloading robot and a second unloading robot arranged in front of and behind each other.

[0011] Furthermore, the palletizing system is provided in two sets along the front and rear of the conveyor belt.

[0012] The benefit of adopting the above-mentioned further solutions is that it improves palletizing efficiency.

[0013] Furthermore, it also includes a flipping mechanism for flipping the target product over.

[0014] The beneficial effect of adopting the above-mentioned further solution is that the flipping mechanism is located on the side of the conveyor belt close to the palletizing robot. When the target product grasped by the next robot is not on the correct side, the next robot can place the grasped target product on the flipping mechanism to flip it over, and the subsequent palletizing robot can accurately grasp the target product and palletize it.

[0015] Furthermore, it also includes a calibration platform, which is located on the same side as the transfer platform.

[0016] The beneficial effect of adopting the above-mentioned further solution is that when the unloading robot arm has a large deviation in grasping the target product, it cannot place it on the transfer platform and can only throw it back onto the conveyor belt. This will cause the target products to pile up on the conveyor belt. The correction platform can work with the unloading robot arm to correct the grasping deviation and prevent the products from piling up on the conveyor belt.

[0017] Furthermore, it also includes one or more pallets, which are within the operating range of the palletizing robot.

[0018] A brake disc stacking method, including the aforementioned brake disc stacking line, wherein the stacking method is as follows:

[0019] 1) The first camera device captures and identifies the target product on the conveyor belt, and transmits the coordinate information of the target product to the next robot arm. The encoder tracks the position of the target product and transmits the distance information to the next robot arm.

[0020] 2) The unloading robot grabs the target product on the conveyor belt and moves it to the second camera device to take a picture. The photo information is then transmitted to the control system.

[0021] 3) The control system calculates the model of the target product, the deviation data between the center point of the target product and the center point of the transfer platform, and then transmits these data to the next robot arm;

[0022] 4) The unloading robot adjusts the placement position of the target product on the transfer platform according to the instructions of the control system, and places the target product with the convex or concave side facing up on the transfer platform;

[0023] 5) The palletizing robot accurately picks up the target product from the transfer table and places it on the pallet;

[0024] 6) Repeat steps 1) to 5) above until the pallets are stacked as required.

[0025] Furthermore, in step 5), the working method of the palletizing robot is as follows: set the initial gripping position of the palletizing robot; move the palletizing robot to the initial gripping position and activate the gripping function; the palletizing robot grabs the target product and moves it to the placement position, adjusts it to the placement height, and then places the target product on the pallet.

[0026] Furthermore, the calculation method for the placement height of the palletizing robot is as follows:

[0027] When L1≥L2-L1, H1:=(2*L1)*(n1-1)+2*L1+h;

[0028] When L1 < L2 - L1, H1: = (L2)*(n1-1) + L2 + h;

[0029] Where L1 is the thickness of the brake surface of the target product, L2 is the height of the target product, H1 is the height of the palletizing robot from the pallet when placing the item, n1 is the number of palletizing layers, n1>=1, and h is the placement height margin, 0mm<h≤10mm.

[0030] Furthermore, the unloading robot first places the target product with its convex side facing up on the transfer platform. The palletizing robot accurately picks up the target product from the transfer platform and stacks it on the pallet with its convex side facing up. When the first layer of the pallet is full, the unloading robot first places the target product with its concave side facing up on the transfer platform. The palletizing robot accurately picks up the target product from the transfer platform and stacks it on the pallet with its concave side facing up. The target products are stacked on the pallet from bottom to top, and the convex and concave sides of the target products are stacked alternately on the pallet.

[0031] Furthermore, when the control system calculates that the deviation between the center point of the target product and the center point of the transfer platform is greater than a threshold, the unloading robot places the target product on the calibration platform according to the instructions of the control system. After adjusting the gripping position, it performs a second gripping of the target product and moves it to the second camera device to take a picture. The unloading robot adjusts the placement position of the target product on the transfer platform according to the instructions of the control system and places the convex or concave surface of the target product on the transfer platform. Attached Figure Description

[0032] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0033] Figure 1 This is a three-dimensional structural diagram of the brake disc palletizing line (a set of palletizing systems) of the present invention;

[0034] Figure 2 This is a three-dimensional structural diagram of the brake disc palletizing line (a set of palletizing systems) of the present invention, which includes an additional unloading robot.

[0035] Figure 3 For the present invention Figure 2 Floor plan;

[0036] Figure 4 This is a plan view of the brake disc palletizing line (dual-group palletizing system) of the present invention;

[0037] Figure 5 This is a front view of the brake disc;

[0038] Figure 6 for Figure 5 Sectional view along axis AA;

[0039] Figure 7 This is a schematic diagram of brake discs stacked on a tray.

[0040] Figure 8 for Figure 7 BB-direction sectional view;

[0041] In the diagram, 1 is a conveyor belt; 2 is the first camera device; 3 is an encoder; 4 is the second camera device; 5 is an unloading robot; 6 is a transfer station; 7 is a palletizing robot; 8 is a calibration table; 9 is a pallet; 10 is a brake disc; and 11 is a tilting mechanism. Detailed Implementation

[0042] The principles and features of the present invention are described below with reference to examples. The examples are only used to explain the present invention and are not intended to limit the scope of the present invention.

[0043] like Figure 1As shown, a brake disc palletizing line includes a conveyor belt 1, a first camera device 2, and an encoder 3. It also includes at least one palletizing system located around the conveyor belt. The palletizing system includes a second camera device 4, a loading robot 5, a transfer station 6, and a palletizing robot 7. The loading robot 5 and the palletizing robot 7 are respectively located on both sides of the conveyor belt 1. The transfer station 6 is located between the conveyor belt 1 and the palletizing robot 7. The line also includes a control system. The control system, the first camera device 2, the encoder 3, the second camera device 4, the loading robot 5, and the palletizing robot 7 are communicatively connected.

[0044] The first camera device 2 is used to identify the target product and transmit the coordinate information of the target product to the unloading robot 5. The encoder 3 is used to track the position of the target product and transmit the distance information to the unloading robot 5. The unloading robot 5 grabs the target product on the conveyor belt 1 and takes a picture at the second camera device 4. The control system calculates the model of the target product and the deviation data between the center point of the target product and the center point of the transfer platform 6 based on the picture taken by the second camera device 4, and then transmits these data to the unloading robot 5. The unloading robot 5 accurately places the target product on the transfer platform 6. Through the brake disc 10 palletizing line and palletizing method of the present invention, manual unloading and palletizing can be replaced. During palletizing, the target product is stacked alternately on the convex and concave surfaces of the pallet 9. Not only can the upper and lower brake discs 10 utilize each other's space and the palletizing is compact, but the robot also works by the set method, and the working stability is high.

[0045] This embodiment does not limit the structure of the first camera device 2 and the second camera device 4. The first camera device 2 and the second camera device 4 can be 3D cameras or 2D cameras. As long as the first camera device 2 can obtain the coordinate position of the target product and the second camera device 4 can obtain the model of the target product and the deviation data between the center point of the target product and the center point of the transfer platform 6, they are all within the protection scope of this invention.

[0046] This embodiment does not limit the number of palletizing systems; the palletizing systems can be one set or multiple sets, as described above. Figures 2-4 Multiple palletizing systems can work simultaneously to improve palletizing efficiency, as long as the production cycle time is met.

[0047] This embodiment does not limit the number of palletizing robots 7 and unloading robots 5. Efficiency can be improved by increasing the number of palletizing robots 7 and / or unloading robots 5 on the production line.

[0048] The palletizing line of the brake disc 10 also includes a flipping mechanism 11, which is used to flip the target product. The flipping mechanism 11 is located on the side of the conveyor belt 1 near the palletizing robot 7. When the target product grasped by the next robot 5 is not on the correct side, the next robot 5 can place the grasped target product on the flipping mechanism 11 to flip it over, so that the subsequent palletizing robot 7 can accurately grasp the target product and palletize it.

[0049] The brake disc 10 palletizing line also includes a calibration table 8, which is located on the same side as the transfer table 6. When the unloading robot 5 has a large deviation in gripping the target product, it cannot place it on the transfer table 6 and must throw it back onto the conveyor belt 1. This causes the target products to stack on the conveyor belt 1. The calibration table 8 can work with the unloading robot 5 to correct the gripping deviation and prevent the products from stacking on the conveyor belt 1.

[0050] The palletizing line of the brake disc 10 also includes one or more pallets 9, which are within the operating range of the palletizing robot 7.

[0051] In this embodiment, the target product is as follows: Figure 5 and 6 The brake disc 10 shown is identified by a 3D camera, which transmits its position as coordinates to the unloading robot 5. An encoder 3 is triggered at a specific location to track the brake disc 10. The unloading robot 5 performs data calculations, tracks and grasps the brake disc 10 on the conveyor belt 1. After grasping, the robot takes the brake disc 10 to a 2D camera for imaging. An algorithm calculates the model number of the brake disc 10 and its deviation from the center point, transmitting this data to the unloading robot 5. The unloading robot 5 processes the data according to the corresponding model and calculates the deviation to precisely place the brake disc 10 onto the transfer platform 6. In this embodiment, each unloading robot 5 corresponds to four transfer platforms 6, enabling simultaneous grasping of two different models of brake discs 10. After receiving the signal indicating placement is complete, the palletizing robot 7 retrieves the corresponding data formula based on the model number and performs grasping and palletizing based on real-time data. During palletizing, the spacing of the brake disc is adjusted by servo according to the large outer diameter, small outer diameter, brake thickness, and other data of different models, so that different models can use different palletizing distances, making the palletizing neat and orderly.

[0052] A brake disc stacking method, including the aforementioned brake disc stacking line, wherein the stacking method is as follows:

[0053] 1) The first camera device 2 captures and identifies the target product on the conveyor belt 1, and transmits the coordinate information of the target product to the next robot arm 5. The encoder 3 tracks the position of the target product and transmits the distance information to the next robot arm 5.

[0054] 2) The unloading robot arm 5 grabs the target product on the conveyor belt 1 and moves it to the second camera device 4 to take a picture. The picture information is then transmitted to the control system.

[0055] 3) The control system calculates the model of the target product and the deviation data between the center point of the target product and the center point of the transfer platform 6, and then transmits these data to the next robot arm 5; the control system obtains the model information of the target product by comparing the photos obtained from the second camera device 4 with the product information in the database.

[0056] 4) The unloading robot 5 adjusts the placement position of the target product on the transfer table 6 according to the instructions of the control system, and places the target product with the convex or concave side facing up on the transfer table 6.

[0057] 5) The palletizing robot 7 accurately picks up the target product from the transfer table 6 and places it on the pallet 9.

[0058] Furthermore, in step 5), the working method of the palletizing robot 7 is as follows: set the initial gripping position of the palletizing robot 7; move the palletizing robot 7 to the initial gripping position and activate the gripping function; the palletizing robot 7 grabs the target product and moves it to the placement position, adjusts it to the placement height, and then places the target product on the pallet 9.

[0059] The method for calculating the placement height of the palletizing robot 7 is as follows:

[0060] When L1≥L2-L1, H1:=(2*L1)*(n1-1)+2*L1+h;

[0061] When L1 < L2 - L1, H1: = (L2)*(n1-1) + L2 + h;

[0062] Where L1 is the thickness of the brake surface of the target product, L2 is the height of the target product, H1 is the height of the palletizing robot 7 from the pallet 9 when placing the product, n1 is the number of palletizing layers, n1>=1, and h is the height allowance for placing the product, 0mm<h≤10mm.

[0063] The unloading robot 5 first places the target product with its convex side facing up on the transfer platform 6. The palletizing robot 7 accurately picks up the target product from the transfer platform 6 and stacks it with its convex side facing up on the pallet 9. When the first layer of the pallet 9 is full, the unloading robot 5 first places the target product with its concave side facing up on the transfer platform 6. The palletizing robot 7 accurately picks up the target product from the transfer platform 6 and stacks it with its concave side facing up on the pallet 9. The target products are stacked sequentially from bottom to top on the pallet 9, with the convex and concave sides of the target products alternating (see reference). Figure 7 and Figure 8 ).

[0064] When the control system calculates that the deviation between the center point of the target product and the center point of the transfer platform 6 is greater than the threshold, the unloading robot 5 places the target product on the calibration platform 8 according to the instructions of the control system. After adjusting the gripping position, it performs a second gripping of the target product and moves it to the second camera device 4 to take a picture. The unloading robot 5 adjusts the placement position of the target product on the transfer platform 6 according to the instructions of the control system and places the convex or concave surface of the target product on the transfer platform 6.

[0065] The brake disc position correction principle is as follows: The left and right positions of the brake disc on the conveyor belt are random. The first camera device can provide the left and right positions of the brake disc on the conveyor belt. In addition, based on this, the encoder can track and determine the front and back positions along the conveyor belt when it reaches the next part position. The unloading robot can adjust the initial gripping position according to these parameters. Then, the unloading robot takes a picture of the gripped brake disc on the second camera device. The second camera device transmits the picture to the control system. The control system determines the model and the deviation from the set placement position of the transfer platform and sends it to the unloading robot. The unloading robot accurately adjusts the placement position according to this and places the brake disc on the transfer platform.

[0066] The palletizing speed of the palletizing line can reach more than 15 pieces per minute, which fully meets the needs of a daily production of more than 20,000 pieces.

[0067] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A brake disc stacking method, comprising a brake disc stacking line, characterized in that, The brake disc palletizing line includes a conveyor belt, a first camera device and an encoder, and at least one palletizing system located around the conveyor belt. The palletizing system includes a second camera device, a loading robot, a transfer station and a palletizing robot. The loading robot and the palletizing robot are respectively located on both sides of the conveyor belt. The transfer station is located between the conveyor belt and the palletizing robot. The line also includes a control system. The control system, the first camera device, the encoder, the second camera device, the loading robot and the palletizing robot are communicatively connected. The first camera device and the second camera device are 3D cameras or 2D cameras; the first camera device is used to identify the initial coordinate position of the brake disc, and the second camera device is used to identify the positional deviation of the brake disc; It also includes a calibration platform, which is located on the same side as the transfer platform; The palletizing method is as follows: 1) The first camera device captures and identifies the target product on the conveyor belt, and transmits the coordinate information of the target product to the next robot arm. The encoder tracks the position of the target product and transmits the distance information to the next robot arm. 2) The unloading robot grabs the target product on the conveyor belt and takes it to the second camera device to take a picture. The photo information is then transmitted to the control system. 3) The control system calculates the model of the target product, the deviation data between the center point of the target product and the center point of the transfer platform, and then transmits this data to the next robot arm; 4) The unloading robot adjusts the placement position of the target product on the transfer platform according to the instructions of the control system, and places the target product with the convex or concave side facing up on the transfer platform; 5) The palletizing robot accurately picks up the target product from the transfer table and places it on the pallet; 6) Repeat steps 1) to 5) until the pallets are stacked as required.

2. The brake disc stacking method according to claim 1, characterized in that, A set of unloading robots in the palletizing system includes a first unloading robot and a second unloading robot arranged in front of and behind each other.

3. The brake disc stacking method according to claim 1 or 2, characterized in that, The palletizing system is provided in two sets along the front and back of the conveyor belt.

4. The brake disc stacking method according to claim 1, characterized in that, In step 5), the working method of the palletizing robot is as follows: set the initial gripping position of the palletizing robot; move the palletizing robot to the initial gripping position and start the gripping function; the palletizing robot grabs the target product and moves it to the placement position, adjusts it to the placement height, and then places the target product on the pallet.

5. The brake disc stacking method according to claim 4, characterized in that, The method for calculating the placement height of a palletizing robot is as follows: When L1≥L2-L1 ; When L1 < L2 - L1 ; Where L1 is the thickness of the brake surface of the target product, L2 is the height of the target product, H1 is the height of the palletizing robot from the pallet when placing the part, n1 is the number of palletizing layers, n1>=1, and h is the height allowance for placing the part, 0mm<h≤10mm.

6. The brake disc stacking method according to claim 4, characterized in that, The unloading robot first places the target product with the convex side facing up on the transfer platform. The palletizing robot accurately picks up the target product from the transfer platform and stacks it on the pallet with the convex side facing up. When the first layer of the pallet is full, the unloading robot first places the target product with the concave side facing up on the transfer platform. The palletizing robot accurately picks up the target product from the transfer platform and stacks it on the pallet with the concave side facing up. The target products are stacked on the pallet from bottom to top, and the convex and concave sides of the target products are stacked alternately on the pallet.

7. The brake disc stacking method according to claim 4, characterized in that, When the control system calculates that the deviation between the center point of the target product and the center point of the transfer platform is greater than the threshold, the unloading robot places the target product on the calibration platform according to the instructions of the control system. After adjusting the gripping position, it performs a second gripping of the target product and moves it to the second camera device to take a picture. The unloading robot adjusts the placement position of the target product on the transfer platform according to the instructions of the control system and places the convex or concave surface of the target product on the transfer platform.

Images