A method for stacking non-uniform fabric rolls

Abstract

This invention discloses a method for palletizing non-uniform specification fabric rolls, relating to the field of fabric roll palletizing technology. The method comprises the following steps: S1. Visually acquiring and analyzing information about the fabric roll; S2. Determining the placement position based on the analyzed information; S3. Activating a palletizing robot, positioning it at the fabric roll gripping position, and gripping the fabric roll; S4. Placing the fabric roll at the determined palletizing position and recording the position; S5. After completing the specified number of layers and quantities for a pallet, sending pallet palletizing completion information and clearing the historical record position for that pallet; S6. Repeating the above steps and palletizing according to the specified number of layers and quantities. This invention solves the technical problem of poor stability and stacking accuracy of palletizing robots when palletizing non-uniform specification fabric rolls in existing technologies, achieving the technical effect of improving the stability and stacking accuracy of palletizing robots when palletizing non-uniform specification fabric rolls.

Description

Technical Field

[0001] This invention relates to the field of fabric roll stacking technology, specifically a method for stacking fabric rolls of non-uniform specifications. Background Technology

[0002] At present, palletizing robots are widely used in the industrial palletizing field. They have replaced traditional manual operations, greatly improving the automation and efficiency of the industry. Palletizing robots can perform precise handling and palletizing operations on workpieces of uniform specifications, greatly reducing manual labor, reducing labor costs, and improving work safety and environmental controllability.

[0003] However, during the stacking process, it is common to encounter situations where workpieces are not of uniform specifications. Due to different customer requirements, the diameter of the fabric rolls may vary during production. In such cases, continuing with the original stacking method will significantly reduce the accuracy and stability of the stacking.

[0004] In order to enable palletizing robots to maintain good stacking accuracy and stability when stacking non-uniform fabric rolls, this invention provides a palletizing method for non-uniform fabric rolls. Summary of the Invention

[0005] The purpose of this invention is to provide a method for stacking non-uniform specification fabric rolls to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a method for stacking non-uniform specification fabric rolls, comprising the following steps:

[0007] S1. Visually acquire and analyze information about the fabric roll;

[0008] S2. Determine the placement position based on the information from the fabric roll analysis;

[0009] S3. Start the palletizing robot, position it at the fabric roll grabbing position, and grab the fabric roll;

[0010] S4. The palletizing robot places the fabric roll at the determined palletizing position and records the position.

[0011] S5. After completing the specified number of layers and quantities for a pallet, send pallet ...

[0012] S6. Repeat the above steps and stack the items according to the specified number of layers and quantities.

[0013] Preferably, in step S1, the information of the fabric roll is obtained by taking a picture of the cross-sectional diameter of the fabric roll with a camera, and by scanning the barcode affixed to the cross-section of the fabric roll to obtain the tray on which the fabric roll needs to be stacked.

[0014] Preferably, after the camera captures and scans the barcode, it analyzes the scanned information. When the cross-sectional diameter of the fabric roll is greater than a certain specified value, it is defined as a large roll workpiece; when the cross-sectional diameter of the fabric roll is less than or equal to a certain specified value, it is defined as a small roll workpiece.

[0015] Preferably, after analyzing and classifying the large and small rolls of workpieces, the large rolls of workpieces in odd-numbered layers are stacked horizontally from both sides of the pallet towards the center, while the small rolls of workpieces are stacked horizontally from the center of the pallet towards both sides. The large rolls of workpieces in even-numbered layers are stacked vertically from the front and back of the pallet towards the center, while the small rolls of workpieces are stacked vertically from the center of the pallet towards the front and back sides. Based on the historical position, the column of the layer where the roll of workpiece should be placed is determined, thus completing the determination of the stacking position.

[0016] Preferably, the gripping position in step S3 refers to the relative position of the target fabric roll in the workpiece coordinate system of the palletizing robot, transmitted by the camera, and the trajectory of the palletizing robot's gripping of the target fabric roll workpiece is obtained by calculation by the palletizing robot controller.

[0017] Preferably, the recording position in step S4 refers to recording the number of layers and columns of the fabric rolls that are stacked. This position enables the palletizing robot to accurately calculate the position where the next fabric roll should be placed, ensuring that the fabric rolls are not repeatedly stacked in the same place.

[0018] Preferably, in step S5, after completing the specified number of layers and quantities, a pallet pallet stacking completion signal is sent to the host computer and the historical stacking information of the pallet is cleared. The pallet is then left to be transported away, and a new pallet is left to be delivered to the designated pallet position.

[0019] Compared with the prior art, the beneficial effects of the present invention are:

[0020] 1. This invention solves the technical problem of poor stability and stacking accuracy of palletizing robots when stacking non-uniform specification cloth rolls in the prior art, and achieves the technical effect of improving the stability and stacking accuracy of palletizing robots when stacking non-uniform specification cloth rolls.

[0021] 2. In this invention, large rolls of workpieces are stacked on both sides of a pallet. Because they are in close contact with the workpieces on the upper layer and have a large frictional force, they can be stacked stably on both sides of the pallet. When small rolls of workpieces are stacked in the middle, even if the stacking is not secure because the cross-sectional diameter of the small rolls of workpieces is smaller than that of the large rolls of workpieces, the large rolls of workpieces on both sides will make the stacking more stable. Attached Figure Description

[0022] Figure 1 Flowcharts of embodiments provided in this application;

[0023] Figure 2 The visual processing flow provided in the embodiments of this application;

[0024] Figure 3 This application provides an embodiment of the small roll workpiece stacking sequence diagram;

[0025] Figure 4 This is a diagram showing the stacking sequence of large roll workpieces provided in the embodiments of this application. Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0027] Please see Figures 1 to 4 This invention provides a technical solution: a method for stacking non-uniform specification fabric rolls, comprising the following steps:

[0028] S1. Visually acquire and analyze information about the fabric roll;

[0029] S2. Determine the placement position based on the information from the fabric roll analysis;

[0030] S3. Start the palletizing robot, position it at the fabric roll grabbing position, and grab the fabric roll;

[0031] S4. The palletizing robot places the fabric roll at the determined palletizing position and records the position.

[0032] S5. After completing the specified number of layers and quantities for a pallet, send pallet ...

[0033] S6. Repeat the above steps and stack the items according to the specified number of layers and quantities.

[0034] In this embodiment, the information of the fabric roll in step S1 is obtained by taking a picture of the cross-sectional diameter of the fabric roll with a camera and by scanning the barcode affixed to the cross-section of the fabric roll to obtain the pallet to which the fabric roll needs to be placed. After taking the picture and scanning the barcode, the camera will analyze the scanned information. When the cross-sectional diameter of the fabric roll is greater than a certain specified value, it is defined as a large roll workpiece; when the cross-sectional diameter of the fabric roll is less than or equal to a certain specified value, it is defined as a small roll workpiece. At the same time, the camera will obtain the position coordinates of the fabric roll in the workpiece coordinate system of the palletizing robot and send them to the palletizing robot controller. The palletizing robot controller will calculate the trajectory of the movement required for the palletizing robot to grasp the target fabric roll workpiece, which enables the palletizing robot to grasp the workpiece more accurately.

[0035] In this embodiment, after classifying the large and small rolls of workpieces, the large rolls of workpieces with odd-numbered layers are stacked horizontally from both sides of the pallet towards the center, while the small rolls of workpieces are stacked horizontally from the center of the pallet towards both sides. The large rolls of workpieces with even-numbered layers are stacked vertically from the front and back of the pallet towards the center, while the small rolls of workpieces are stacked vertically from the center of the pallet towards both the front and back sides. The specific column of the layer where the roll needs to be stacked is determined based on the historical position, thus completing the determination of the stacking position. After the stacking of the roll is completed, the number of layers and columns of the roll is recorded. This position allows the palletizing robot to accurately calculate the position of the next roll, ensuring that the rolls are not repeatedly stacked in the same place.

[0036] The reason for this stacking method is that, during industrial production, customers order fabrics of varying lengths. When these fabric rolls are rolled into cylinders, their cross-sectional diameters differ, resulting in variations. If these differently sized rolls are stacked sequentially, the stability and accuracy of the stacking process would be significantly reduced. The stacking method described in this application effectively solves this problem. Larger rolls are placed on either side of the pallet because their own pressure and the compression from the upper layers of workpieces cause deformation. This deformation greatly increases the contact area between the lower surface of the larger roll and the pallet, thus increasing friction. Simultaneously, because the cross-sectional diameter of the larger roll is larger than that of the smaller roll, if smaller rolls are placed on either side of the pallet, the height of the larger roll in the middle will be greater than the height of the smaller rolls. This will prevent the smaller rolls from being properly compacted by the upper layers, creating gaps. When the pallet is moved too quickly, there is a risk that the uncompacted smaller rolls on both sides may be thrown out. When large rolls of workpiece are stacked on either side of a pallet, they remain firmly in place due to close contact with the workpieces above and their inherent high friction. Smaller rolls of workpiece are then placed in the middle. Even if the stacking is initially unstable due to the smaller cross-sectional diameter of the smaller rolls, the stability is enhanced by the firmly secured larger rolls on either side.

[0037] In this embodiment, the gripping position mentioned in step S3 refers to the relative position of the target fabric roll in the workpiece coordinate system of the palletizing robot, transmitted by the camera. The trajectory of the palletizing robot's movement to grip the target fabric roll is obtained by the calculation of the palletizing robot controller. The recording position mentioned in step S4 refers to recording the number of layers and columns of the fabric roll that have been stacked. This position enables the palletizing robot to accurately calculate the position to be stacked next, ensuring that the fabric rolls are not repeatedly stacked in the same place. After completing the specified number of layers and quantities, the pallet is sent to the host computer with a pallet stacking completion signal and the historical stacking information of the pallet is cleared. The pallet is then left to be transported away, and a new pallet is left to be delivered to the designated pallet position.

[0038] Working principle: In actual production, when the fabric roll arrives at the fabric roll information detection point along the conveyor belt, a photoelectric switch is triggered to activate the fabric roll information detection camera. The camera collects the cross-sectional diameter of the fabric roll, its target pallet, and its coordinates in the palletizing robot tool coordinate system. The vision processing flow is as follows: Figure 2 As shown. To improve image processing speed and reduce processing time, a specific area can be selected for focused analysis. Considering all factors, the key image area can be set according to the following rules: ensure the cross-sectional area of ​​the fabric roll occupies approximately three-quarters of the image area. Referring to the principle of center imaging, the formula for calculating the camera working distance can be obtained, namely:

[0039]

[0040] In the formula: μ is the pixel size; N is the number of pixels occupied by the object image in a single direction; f is the camera focal length; l is the actual size of the object; d is the distance between the camera lens and the object being measured.

[0041] Considering the noise in the center of the captured image caused by component vibration or the interaction of circuit elements, Gaussian filtering is used for noise reduction. The Gaussian function is as follows:

[0042]

[0043] The robot controller calculates the specific placement position of the fabric roll. For example, if the cross-sectional diameter of the fabric roll is greater than 250mm, we define it as a large roll and it needs to be stacked sequentially from both sides of the target pallet towards its center. Figure 3 As shown, when the cross-sectional diameter of the fabric roll is less than or equal to 250 mm, it is defined as a small roll and needs to be stacked sequentially from the center of the target palletizing pallet to both sides. Figure 4 As shown. Specifically:

[0044] When the first fabric roll workpiece A arrives at the fabric roll information detection point, its detection result is a small roll workpiece, and its target palletizing pallet is pallet 1. Then, the palletizing robot starts running to the coordinates of workpiece A obtained from the camera and grabs it. After grabbing, based on the fact that fabric roll A is a small roll workpiece and the target palletizing pallet 1 is selected, the palletizing robot runs to the center position of the first layer of pallet 1, places workpiece A, and records the placement information of the workpiece. Then, it returns to the origin of the palletizing robot to complete one stacking of fabric rolls, and the palletizing robot enters a waiting state.

[0045] When the second fabric roll workpiece B arrives at the workpiece information detection point, its detection result is a large roll workpiece with target pallet 1. The palletizing robot will then place it on the far left of pallet 1 based on the detection result and historical placement information. If the detection result is still a small roll workpiece with target pallet 1, the palletizing robot will place it on the right side, immediately adjacent to workpiece A, based on the detection result and historical placement information. After completing the placement of workpiece B, the historical placement information is updated, and the palletizing robot returns to its origin and enters a waiting state.

[0046] When the three fabric roll workpieces C arrive at the fabric roll information detection point, if the detection result is a large roll workpiece and the target pallet is pallet 1, then the palletizing robot will place it on the far right of pallet 1 according to the detection result and historical stacking information. If the detection result is a small roll workpiece and the target pallet is 1, then the palletizing robot will place it on the left side, right next to workpiece A.

[0047] This process is repeated until more than five rolls of fabric are stacked on pallet 1. The next roll is then placed vertically on the second layer. If it is a small roll, it is placed from the middle of the second layer to both sides in the same order as the first layer. If it is a large roll, it is placed from both sides to the middle in the same order as the first layer. This process of stacking odd-numbered layers vertically and even-numbered layers horizontally continues until the specified number of rolls or layers is reached.

[0048] When a pallet, such as pallet 1, is stacked to a specified quantity or layer, the historical stacking record of pallet 1 is cleared, and the palletizing robot controller sends a "pallet full" signal to the host computer for processing until a new pallet is placed in the original position of pallet 1. During this process, if the fabric roll workpiece information detection point detects a fabric roll workpiece that needs to be stacked on pallet 1, the palletizing robot will not take any action, will stop the stacking operation, and will wait for the new pallet 1 to be placed. If it is detected that the workpiece needs to be stacked on another pallet, the stacking operation will continue.

[0049] Before this embodiment can accurately implement the above palletizing method, it is necessary to debug the palletizing robot. The debugging includes: debugging one to determine the coordinate point one of each pallet where the cloth rolls need to be placed. The offset command in the palletizing robot can be used through the coordinate point one to realize the coordinate offset required when placing the cloth rolls according to the offset command. By combining the historical palletizing information of a target pallet with calculations by the palletizing robot controller and offset commands, the accurate target coordinates for fabric roll placement can be obtained. The second step, debugging, determines the coordinates of the fabric roll gripping point, i.e., the coordinates of the fabric roll information detection point. After the fabric roll reaches the information detection point, it is detected by a machine vision camera. This series of information includes the relative position of the fabric roll in the workpiece coordinate system of the palletizing robot. To enable the palletizing robot to accurately grip the target fabric roll, this relative position needs to be converted. An auxiliary coordinate point can be determined in the workpiece coordinate system. This auxiliary coordinate point is calculated by comparing the relative position sent by the robot controller and the camera to determine the offset required for the palletizing robot to reach the relative position from this auxiliary point. The target fabric roll can be accurately gripped by combining the offset commands with this offset.

[0050] Based on the above, the present invention solves the technical problem of poor stability and stacking accuracy of palletizing robots when stacking non-uniform specification cloth rolls in the prior art, and achieves the technical effect of improving the stability and stacking accuracy of palletizing robots when stacking non-uniform specification cloth rolls.

[0051] As is known from common technical knowledge, this invention can be implemented through other embodiments that do not depart from its spirit or essential characteristics. Therefore, the disclosed embodiments described above are merely illustrative and not exhaustive. All modifications within the scope of this invention or its equivalents are included in this invention.

Claims

1. A method for stacking non-uniform specification fabric rolls, characterized in that: Includes the following steps: S1. Visually acquire and analyze information about the fabric roll; S2. Determine the placement position based on the information from the fabric roll analysis; S3. Start the palletizing robot, position it at the fabric roll grabbing position, and grab the fabric roll; S4. The palletizing robot places the fabric roll at the determined palletizing position and records the position. S5. After completing the specified number of layers and quantities for a pallet, send pallet ... S6. Repeat the above steps and stack the items according to the specified number of layers and quantities; In step S1, the information of the fabric roll is obtained by taking a picture of the cross-sectional diameter of the fabric roll with a camera and by scanning the barcode affixed to the cross-section of the fabric roll to obtain the tray on which the fabric roll needs to be stacked. After the camera captures and scans the barcode, it analyzes the scanned information. When the cross-sectional diameter of the fabric roll is greater than a certain specified value, it is defined as a large roll workpiece; when the cross-sectional diameter of the fabric roll is less than or equal to a certain specified value, it is defined as a small roll workpiece. After analyzing and classifying the large and small rolls of workpiece, large rolls of workpiece with odd-numbered layers are stacked horizontally from the left and right sides of the pallet toward the center, while small rolls of workpiece are stacked horizontally from the center of the pallet toward the left and right sides. Large rolls of workpiece with even-numbered layers are stacked vertically from the front and back sides of the pallet toward the center, while small rolls of workpiece are stacked vertically from the center of the pallet toward the front and back sides. Based on the historical position, the specific column of the layer where the roll of workpiece needs to be stacked is determined, thus completing the determination of the stacking position. The recording of the position in step S4 refers to recording the number of layers and columns of the fabric rolls that have been stacked. This position enables the palletizing robot to accurately calculate the position of the next fabric roll, ensuring that the fabric rolls are not repeatedly stacked in the same place.

2. The method for stacking non-uniform specification fabric rolls according to claim 1, characterized in that: The gripping position mentioned in step S3 refers to the relative position of the target fabric roll in the workpiece coordinate system of the palletizing robot, transmitted by the camera. The trajectory of the palletizing robot's gripping of the target fabric roll workpiece is obtained by the calculation of the palletizing robot controller.

3. The method for stacking non-uniform specification fabric rolls according to claim 1, characterized in that: In step S5, after completing the specified number of layers and quantities, a pallet pallet stacking completion signal is sent to the host computer and the historical stacking information of the pallet is cleared. The system then waits for the completed pallet to be transported away and for a new pallet to be delivered to the designated pallet position.

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