Detection control system for cutting position of large-size cutting product

Abstract

The application provides a large-size cutting product cutting position detection control system, which comprises a horizontal holder, an image acquisition module, a side gauge driving module and an information processing module. The image acquisition module comprises an industrial camera, a light source and a support. The support is arranged on the horizontal holder, and the industrial camera and the light source are movably connected with the support. The support comprises an arc-shaped support. The side gauge driving module comprises a side gauge, a stepping motor and a position sensor. The stepping motor is used for adjusting the side gauge, and the position sensor is used for feeding back the size of the side gauge adjusted by the stepping motor. The information processing module is used for acquiring an image collected by the image acquisition module, obtaining a deviation value of a cutting line of the image and a template according to the image, and controlling the stepping motor to adjust the side gauge according to the deviation value. The application can more accurately and directly measure the deviation size of the side gauge, improve the cutting quality of the product, and reduce the participation of manual work.

Description

Technical Field

[0001] This application relates to the field of cutting position detection technology for cut products, and more specifically, to a detection and control system for the cutting position of large sheets of cut products. Background Technology

[0002] In the automated cutting process of large sheets of securities, it is crucial to ensure the absolute accuracy of the product's posture to guarantee the dimensional accuracy of the cut product. Initially, the cutting process lacks any inspection mechanism. Once the product reaches the cutting position, side guides tap and adjust its orientation to ensure proper positioning. After positioning, the cutting blade initiates the cutting process. This method presents a significant risk: if the product's posture deviates considerably, the side guides fail to provide effective correction, resulting in scrapped products.

[0003] With the upgrading of detection technology, after the side guide tapping is completed, four cameras installed directly above the product check the posture of the product face sheet. If the check is within the error range, the cutting action can be started. However, this detection method has a defect: if the product face sheet is misaligned with the product below, the quality of the product below cannot be effectively guaranteed after cutting.

[0004] During the large-sheet cutting process, since the printed materials are not printed on the same printing press, the positioning reference for each stack of products is different. Therefore, during cutting, it is necessary to check whether the cutting line of each stack coincides with the actual cutting position. When the deviation is too large, the machine needs to be stopped and two people need to work together to adjust the side gauge. Since the gauge edge is on the non-operational side, both cutting positions on both sides need to be taken into account, so two people need to work together. During the side gauge adjustment process, both operators are required to communicate to adjust the side gauge size. However, each person has a different understanding of the gauge size, so there may be information gaps in the communication process, leading to errors in the adjustment size. Summary of the Invention

[0005] This application aims to solve at least one of the aforementioned technical problems.

[0006] Therefore, the primary objective of this application is to provide a detection and control system for the cutting position of large-sheet cut products.

[0007] To achieve the first objective of this application, the first aspect of the present invention provides a detection and control system for the cutting position of large-sheet cut products, comprising: a horizontal pan-tilt unit; an image acquisition module including an industrial camera, a light source, and a support, the support being mounted on the horizontal pan-tilt unit, the industrial camera and the light source being movably connected to the support, the support including an arc-shaped support; a side guide drive module, located on one side of the horizontal pan-tilt unit, the side guide drive module including a side guide, a stepper motor, and a position sensor, the stepper motor being connected to the side guide for adjusting the side guide, the position sensor being connected to the stepper motor for providing feedback on the size of the side guide adjusted by the stepper motor; and an information processing module, connected to the image acquisition module and the side guide drive module respectively, the information processing module being used to acquire the image acquired by the image acquisition module, and to obtain the deviation value between the cutting line of the image and the template based on the image, and to control the stepper motor to adjust the side guide based on the deviation value.

[0008] In this technical solution, the detection and control system for the cutting position of large-sheet products includes a horizontal pan-tilt head, an image acquisition module, a side guide drive module, and an information processing module. The image acquisition module includes an industrial camera, a light source, and a support. The camera support is mounted on the horizontal pan-tilt head, expanding the shooting range to accommodate all varieties of large-sheet products and ensuring the optimal shooting position. The industrial camera and light source are movably connected to the curved support, allowing adjustment of the camera's shooting angle. Adjusting the industrial camera's position eliminates the need to adjust its focal length, saving adjustment time. The side guide drive module includes a side guide, a stepper motor, and a position sensor. The stepper motor adjusts the side guide, and after adjustment, a high-precision position sensor mounted on one side provides feedback on the stepper motor's adjusted side guide dimensions, achieving closed-loop control in the program. Using a stepper motor to drive the side guide size adjustment enables real-time automatic adjustment of the side guide dimensions. After the image acquisition module completes its image acquisition task, the information processing module acquires the image, compares the cutting line on the image with the template, obtains the deviation value between the cutting line and the template, and controls the stepper motor to adjust the corresponding parameters of the side guide based on the deviation value. After adjustment, the values ​​are compared with those from the position sensor to ensure the accuracy of the motor adjustment parameters. The stepper motor adjustment accuracy can reach 0.02mm, significantly improving the side gauge adjustment accuracy. This application's technical solution can more accurately and directly measure the deviation dimensions of the side gauge, improving the product cutting quality. By using an arc-shaped camera bracket, adjusting the industrial camera position does not require adjusting the focal length, while still meeting data usage requirements. Applying stepper motor-driven side gauge parameter adjustment allows for both manual intervention and fully automatic adjustment of the side gauge dimensions, simplifying and speeding up the process, reducing manual labor, significantly improving work efficiency, and minimizing downtime during side gauge adjustment.

[0009] In addition, the technical solution provided in this application may also have the following additional technical features:

[0010] In the above technical solution, optionally, the arc-shaped bracket is a 45° arc-shaped bracket with the downward cut of the cutting blade as the center and the distance from the cutting blade to the center line of the horizontal gimbal as the radius.

[0011] In this technical solution, the arc-shaped support is a 45° arc-shaped support with the downward cut of the cutting blade as the center and the distance from the cutting blade to the center line of the horizontal gimbal as the radius. When adjusting the position of the industrial camera, it is not necessary to adjust the focal length of the industrial camera, thus saving adjustment time.

[0012] Optionally, in the above technical solution, the horizontal gimbal includes a first horizontal gimbal and a second horizontal gimbal, with the first horizontal gimbal and the second horizontal gimbal being spaced apart.

[0013] In this technical solution, the horizontal gimbal includes a first horizontal gimbal and a second horizontal gimbal, which are spaced apart.

[0014] Optionally, in the above technical solution, the arc-shaped bracket includes a first arc-shaped bracket and a second arc-shaped bracket, the first arc-shaped bracket being connected to a first horizontal gimbal, and the second arc-shaped bracket being connected to a second horizontal gimbal.

[0015] In this technical solution, the arc-shaped bracket includes a first arc-shaped bracket and a second arc-shaped bracket. The first arc-shaped bracket is connected to a first horizontal gimbal, and the second arc-shaped bracket is connected to a second horizontal gimbal.

[0016] In the above technical solution, optionally, the industrial camera includes a front-end cutting line camera and a rear-end cutting line camera, the front-end cutting line camera is movably connected to the first arc-shaped bracket, and the rear-end cutting line camera is movably connected to the second arc-shaped bracket.

[0017] In this technical solution, the industrial camera includes a front-end cutting line camera and a rear-end cutting line camera. The front-end cutting line camera is movably connected to a first arc-shaped bracket, and the rear-end cutting line camera is movably connected to a second arc-shaped bracket.

[0018] In the above technical solution, optionally, the light source includes a first light source and a second light source, the first light source being connected to the front-end cutting line camera and the second light source being connected to the rear-end cutting line camera.

[0019] In this technical solution, the light source includes a first light source and a second light source. The first light source is connected to the front-end cutting line camera, and the second light source is connected to the rear-end cutting line camera.

[0020] In the above technical solution, optionally, the information processing module includes a computer connected to an industrial camera, used to acquire images captured by the industrial camera, and to calculate the deviation value between the image's cutting line and the template based on the image.

[0021] In this technical solution, the information processing module includes a computer connected to an industrial camera to acquire images captured by the industrial camera and calculate the deviation between the image's cutting line and the template based on the images.

[0022] Optionally, in the above technical solution, the information processing module also includes a PLC, which is connected to a computer and a stepper motor respectively, and is used to control the stepper motor to adjust the corresponding parameters of the side gauge according to the deviation value.

[0023] In this technical solution, the information processing module also includes a PLC, which is connected to a computer and a stepper motor respectively, and is used to control the stepper motor to adjust the corresponding parameters of the side gauge according to the deviation value.

[0024] Optionally, in the above technical solution, the detection and control system for the cutting position of large sheet cut products also includes: an alarm device connected to the information processing module, used to trigger an alarm when the deviation value is greater than a preset value.

[0025] In this technical solution, the detection and control system for the cutting position of large-sheet cut products also includes an alarm device. This alarm device is connected to the information processing module and is used to issue an alarm when the deviation value exceeds a preset value. The alarm device prevents the previous situation of scrapping the product with a single cut, thus ensuring the cutting quality of the product.

[0026] Optionally, in the above technical solution, the PLC is also connected to an alarm device to control the alarm device to sound an alarm when the deviation value is greater than a preset value.

[0027] In this technical solution, the PLC is also connected to an alarm device to control the alarm device to sound an alarm when the deviation value is greater than a preset value.

[0028] Optionally, in the above technical solution, the alarm device includes an alarm light.

[0029] In this technical solution, the alarm device can be an alarm light.

[0030] Additional aspects and advantages of this application will become apparent in the following description or may be learned by practice of this application. Attached Figure Description

[0031] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0032] Figure 1 This is a three-dimensional structural diagram of a detection and control system for the cutting position of a large sheet of cut material according to an embodiment of this application;

[0033] Figure 2This is an electrical control schematic diagram of a detection and control system for the cutting position of a large sheet of cut material according to an embodiment of this application;

[0034] Figure 3 This is a flowchart illustrating the side gauge adjustment process of a detection and control system for the cutting position of large-sheet cut products according to an embodiment of this application.

[0035] Figure 4 This is a schematic diagram of an AB blade edge station and an image acquisition camera for a detection and control system of the cutting position of a large sheet of cut material according to an embodiment of this application.

[0036] in, Figure 1 The correspondence between the reference numerals and component names in the attached drawings is as follows:

[0037] 10: Detection and control system for the cutting position of large sheet cut products; 110: Horizontal pan-tilt head; 120: Industrial camera; 130: Arc bracket; 140: Stepper motor. Detailed Implementation

[0038] To better understand the above-mentioned objectives, features, and advantages of this application, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0039] Many specific details are set forth in the following description in order to provide a full understanding of this application. However, this application may also be implemented in other ways different from those described herein. Therefore, the scope of protection of this application is not limited to the specific embodiments disclosed below.

[0040] The following reference Figures 1 to 4 This application describes a detection and control system for the cutting position of large sheets of cut materials, based on some embodiments.

[0041] like Figure 1 and Figure 2As shown, an embodiment of the first aspect of the present invention provides a detection and control system 10 for the cutting position of large sheets of cut products, comprising: a horizontal pan-tilt unit 110; an image acquisition module including an industrial camera 120, a light source, and a support, the support being mounted on the horizontal pan-tilt unit 110, the industrial camera 120 and the light source being movably connected to the support, the support including an arc-shaped support 130; a side guide drive module, located on one side of the horizontal pan-tilt unit 110, the side guide drive module including a side guide, a stepper motor 140, and a position sensor, the stepper motor 140 being connected to the side guide for adjusting the side guide, the position sensor being connected to the stepper motor 140 for providing feedback on the size of the side guide adjusted by the stepper motor 140; an information processing module, connected to the image acquisition module and the side guide drive module respectively, the information processing module for acquiring the image acquired by the image acquisition module, and obtaining the deviation value between the cutting line of the image and the template based on the image, and controlling the stepper motor 140 to adjust the side guide based on the deviation value; and an alarm device, connected to the information processing module, for triggering an alarm when the deviation value is greater than a preset value.

[0042] In this embodiment, the detection and control system 10 for the cutting position of large-sheet cut products includes a horizontal pan-tilt head 110, an image acquisition module, a side guide drive module, and an information processing module. The image acquisition module includes an industrial camera 120, a light source, and a support. The camera support is mounted on the horizontal pan-tilt head 110, which expands the shooting range, accommodating all varieties of large-sheet products and ensuring the optimal shooting position. The industrial camera 120 and the light source are movably connected to the arc-shaped support 130, allowing adjustment of the camera's shooting angle. When adjusting the position of the industrial camera 120, it is not necessary to adjust its focal length, saving adjustment time. The side guide drive module includes a side guide, a stepper motor 140, and a position sensor. The stepper motor 140 is used to adjust the side guide. After the stepper motor 140 has adjusted, the high-precision position sensor mounted on one side provides feedback on the stepper motor 140's adjustment of the side guide's size, achieving closed-loop control in the program. Using a stepper motor 140 to drive the adjustment of the side gauge dimensions enables real-time automatic adjustment. After the image acquisition module completes its image acquisition task, the information processing module acquires the image and compares the cutting line on the image with the template to obtain the deviation value. Based on the deviation value, the stepper motor 140 is controlled to adjust the corresponding parameters of the side gauge. After adjustment, the values ​​are compared with the position sensor changes to ensure the accuracy of the motor adjustment parameters. The stepper motor 140 adjustment accuracy can reach 0.02mm, significantly improving the side gauge adjustment precision. An alarm device is used to sound an alarm when the deviation value exceeds a preset value, preventing the previous situation of scrapping the cut and ensuring the cutting quality of the product. This embodiment can more accurately and directly measure the deviation dimension of the side gauge, improving the cutting quality of the product. By using an arc-shaped camera bracket, the focus does not need to be adjusted when adjusting the position of the industrial camera 120, and the data usage requirements are met. The side gauge parameters are adjusted by using a stepper motor 140. When adjusting the side gauge size, manual intervention or a fully automatic method can be used. It is simple and quick, reduces manual labor, greatly improves work efficiency, and reduces downtime for side gauge adjustment.

[0043] In the above embodiments, optionally, the arc-shaped bracket 130 is a 45° arc-shaped bracket with the cutting blade as the center and the distance from the cutting blade to the center line of the horizontal gimbal 110 as the radius. When adjusting the position of the industrial camera 120, it is not necessary to adjust the focal length of the industrial camera 120, thus saving adjustment time.

[0044] In the above embodiments, optionally, the horizontal gimbal 110 includes a first horizontal gimbal 110 and a second horizontal gimbal 110, with the first horizontal gimbal 110 and the second horizontal gimbal 110 being spaced apart.

[0045] In the above embodiments, optionally, the arc-shaped bracket 130 includes a first arc-shaped bracket 130 and a second arc-shaped bracket 130, the first arc-shaped bracket 130 being connected to the first horizontal gimbal 110, and the second arc-shaped bracket 130 being connected to the second horizontal gimbal 110.

[0046] In the above embodiments, optionally, the industrial camera 120 includes a front-end cutting line camera and a rear-end cutting line camera, the front-end cutting line camera being movably connected to the first arc-shaped bracket 130, and the rear-end cutting line camera being movably connected to the second arc-shaped bracket 130.

[0047] In the above embodiments, optionally, the light source includes a first light source and a second light source, the first light source being connected to the front-end cutting line camera and the second light source being connected to the rear-end cutting line camera.

[0048] In the above embodiments, optionally, the information processing module includes a computer connected to the industrial camera 120, used to acquire images captured by the industrial camera 120 and calculate the deviation value between the image's cutting line and the template based on the images. The information processing module also includes a PLC connected to both the computer and a stepper motor 140, used to control the stepper motor 140 to adjust the corresponding parameters of the side gauge based on the deviation value. The PLC is also connected to an alarm device, used to control the alarm device to sound an alarm when the deviation value exceeds a preset value.

[0049] In the above embodiments, the alarm device may optionally be an alarm light.

[0050] like Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, a detection and control system 10 for the cutting position of large-sheet cut securities, according to a specific embodiment of this application, solves the problem of measuring the position of the product, the paper distribution, and the skew size during the large-sheet cutting process, and collecting serial number information. It provides alarms and deviation values ​​when abnormalities occur. The system comprises advanced technologies such as an industrial camera 120, PLC control technology, and stepper motor 140 drive technology.

[0051] Existing large-sheet cutting process early warning systems add two cameras between a set of knife boxes at the edge-cutting station to collect data at two marker points at the center of the product to determine positional deviation. During printing, variations in printing press pressure can cause paper separation. When the printing press pressure is too high, the product is compressed and deformed, increasing its size. While the deviation at the four detection points near the center is within acceptable limits, it cannot guarantee the cutting accuracy requirements near the product edge. Therefore, our technology uses two 120mm industrial cameras to collect data on the edge cutting line of the large sheet and to determine if the first sheet is misaligned. Only two cameras are used in the center of the product: one to collect the serial number and the other to collect data on marker deviation. These cameras then align the cutting surface to prevent product skewing.

[0052] The image acquisition module consists of an industrial camera 120, a light source, and a support. Structurally, this module needs to capture the front and rear cutting lines of a large product sheet. However, considering the variety of products, the cutting line positions vary. To ensure the optimal shooting position, the camera support is mounted on a horizontal pan-tilt head 110, expanding the shooting range. To adjust the camera's shooting angle, a 45° arc-shaped camera support is constructed with the cutting blade's downward stroke as the center and the distance from the cutting blade to the pan-tilt head's center line as the radius. This eliminates the need to adjust the camera's focus when adjusting the camera position, saving adjustment time.

[0053] The original method for adjusting the side gauge dimensions involved the operator rotating the adjustment handle on the operating side, with a dial indicator fixed above the handle to monitor the adjustment value in real time. We have improved the side gauge adjustment method by upgrading the adjustment handle to a stepper motor drive. After the stepper motor 140 has finished adjusting, a high-precision position sensor mounted on one side provides feedback on the stepper motor 140's adjustment of the side gauge dimensions, achieving closed-loop control in the program.

[0054] Using a stepper motor to drive the adjustment of the side gauge dimensions enables real-time automatic adjustment. After the image acquisition module completes the image acquisition task, it compares the cutting line on the image with the template and transmits the deviation value to the computer. The computer then transmits the deviation value to the PLC to control the stepper motor 140 to adjust the corresponding parameters of the side gauge. After adjustment, the value is compared with the change value from the position sensor to ensure the accuracy of the motor adjustment parameters. The stepper motor 140's adjustment accuracy can reach 0.02mm, significantly improving the side gauge adjustment precision.

[0055] Simultaneously, the system allows for manual adjustment of the side gauge dimensions. After the acquired data is transmitted to the computer, the computer presents the deviation parameters as suggested values ​​to the operator. The operator then adjusts the side gauge dimensions by comparing the acquired images with the actual position of the product on the operating side and adding subjective human judgment.

[0056] Compared to previous operating methods, both automatic and manual adjustment of the side gauge dimensions can reduce manual labor, significantly improve work efficiency, and reduce downtime for side gauge adjustment.

[0057] This embodiment enables more accurate and direct measurement of the deviation dimensions of the side gauge, improving the cutting quality of the product. When collecting data from the edge of a large sheet of product, due to the camera's position, it cannot be perpendicular to the cutting line. An innovative use of an arc-shaped camera bracket eliminates the need to adjust the focus when positioning the camera, while still meeting data usage requirements. During side gauge adjustment, a stepper motor is innovatively applied to drive the adjustment of side gauge parameters. Adjusting the side gauge dimensions can be done manually or automatically, offering convenience and speed. The application of this process control and early warning system eliminates the previous situation of scrapping the cut in one go, ensuring the cutting quality of the product while reducing manual intervention and lowering the labor intensity of employees.

[0058] In this application, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance; the term "multiple" refers to two or more unless otherwise expressly defined. The terms "install," "connect," "link," and "fix" should be interpreted broadly. For example, "connect" can mean a fixed connection, a detachable connection, or an integral connection; "link" can mean a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0059] In the description of this application, it should be understood that the terms "upper", "lower", "rear", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or unit referred to must have a specific orientation or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0060] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0061] The above are merely preferred embodiments of this application and are not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A detection and control system for the cutting position of large-sheet cut products, characterized in that, include: Horizontal gimbal; An image acquisition module includes an industrial camera, a light source, and a support. The support is mounted on the horizontal pan-tilt head. The industrial camera and the light source are movably connected to the support. The support includes an arc-shaped support. A side gauge drive module is located on one side of the horizontal gimbal. The side gauge drive module includes a side gauge, a stepper motor, and a position sensor. The stepper motor is connected to the side gauge and is used to adjust the side gauge. The position sensor is connected to the stepper motor and is used to provide feedback on the stepper motor's adjustment of the side gauge's size. An information processing module is connected to the image acquisition module and the side guide drive module, respectively. The information processing module is used to acquire the image acquired by the image acquisition module, obtain the deviation value between the image's cutting line and the template based on the image, and control the stepper motor to adjust the side guide based on the deviation value. After the collected data is transmitted to the computer, the deviation parameters are presented as suggested values. The arc-shaped bracket is a 45° arc-shaped bracket with the lower blade of the cutting blade as the center and the distance from the cutting blade to the center line of the horizontal gimbal as the radius. The horizontal gimbal includes a first horizontal gimbal and a second horizontal gimbal, which are spaced apart. The arc-shaped support includes a first arc-shaped support and a second arc-shaped support, wherein the first arc-shaped support is connected to the first horizontal gimbal, and the second arc-shaped support is connected to the second horizontal gimbal. Two industrial cameras are used to capture the position of the edge cutting line of the large product and to determine whether the first product is misaligned. The industrial camera includes a front-end cutting line camera and a rear-end cutting line camera. The front-end cutting line camera is movably connected to the first arc-shaped bracket, and the rear-end cutting line camera is movably connected to the second arc-shaped bracket. The information processing module is further used for: After the side gauge is adjusted, the change value is compared with that of the position sensor. The detection and control system for the cutting position of the large sheet of cut product also includes: Multiple cameras are used to align the cutting surface, including cameras that collect the product's serial number and cameras that collect deviations of markers.

2. The detection and control system for the cutting position of large-sheet cut products according to claim 1, characterized in that, The light source includes a first light source and a second light source. The first light source is connected to the front-end cutting line camera, and the second light source is connected to the rear-end cutting line camera.

3. The detection and control system for the cutting position of large-sheet cut products according to claim 1 or 2, characterized in that, The information processing module includes a computer connected to the industrial camera, used to acquire images captured by the industrial camera and calculate the deviation value between the cutting line of the image and the template based on the images.

4. The detection and control system for the cutting position of large-sheet cut products according to claim 3, characterized in that, The information processing module also includes a PLC, which is connected to the computer and the stepper motor respectively, and is used to control the stepper motor to adjust the corresponding parameters of the side gauge according to the deviation value.

5. The detection and control system for the cutting position of large-sheet cut products according to claim 4, characterized in that, Also includes: An alarm device, connected to the information processing module, is used to trigger an alarm when the deviation value exceeds a preset value.

6. The detection and control system for the cutting position of large-sheet cut products according to claim 5, characterized in that, The PLC is also connected to the alarm device and is used to control the alarm device to sound an alarm when the deviation value is greater than a preset value.

7. The detection and control system for the cutting position of large-sheet cut products according to claim 6, characterized in that, The alarm device includes an alarm light.

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