A high-precision palletizer intelligent control system

Abstract

The present invention belongs to the field of palletizer control technology, and particularly relates to a palletizer positioning control technology. Specifically, a high-precision intelligent control system for a palletizer is disclosed. The ideal coordinates of each storage location on a shelf are obtained by a three-dimensional rectangular coordinate system established based on a shelf placement area, and the actual coordinates of the storage location to be stacked are obtained by performing feature scanning of the storage location to be stacked using a visual sensor. At the same time, the positioning coordinates based on the control input and the execution coordinates of the execution terminal in the historical execution record of the palletizer are retrieved to obtain the execution deviation of the palletizer. Thus, the actual coordinates of the storage location to be stacked, the ideal coordinates and the execution deviation of the palletizer are used for positioning control, thereby realizing high-precision positioning control of palletizing based on machine vision, greatly improving the accuracy and reliability of material stacking, being conducive to improving the stability of the stacking, and minimizing the risk of material falling.

Description

Technical Field

[0001] The invention belongs to the technical field of palletizer control, in particular to a positioning control technology for a palletizer, and specifically discloses a high-precision intelligent control system for a palletizer. Background Art

[0002] In the traditional cargo stacking process, manual operation may face the problems of high repetitiveness and high labor intensity, which can easily lead to worker fatigue and accidental injuries. The application of palletizers can effectively reduce these risks and improve stacking efficiency while protecting the safety of workers.

[0003] The control of cargo stacking using a palletizer mainly involves positioning control, path control, and action control. Positioning control is the basis of all controls. Good positioning can ensure that the stacker can accurately place the cargo in the predetermined position when performing the stacking action, avoiding problems such as unstable stacking or misalignment. This is crucial to ensuring the stability and safety of the stacking.

[0004] Although the Chinese invention patent with publication number CN116495495A provides a material positioning method, a control method for a palletizing device and a palletizing system, by obtaining the corresponding position information of the loading position in the matrix set, the unit value of the matrix set on each coordinate axis of the preset coordinate system is determined; and then the coordinate position of the loading position in the preset coordinate system is obtained according to the unit value and the position information of the loading position.

[0005] Although the above scheme provides a deviation compensation method to achieve material storage location when the material placement position is not ideal, this positioning is ultimately only implemented based on the constructed coordinates, and does not take into account the storage location deviation caused by reasons such as the sinking of the ground where the shelf is located and the change of shelf load. As a result, there is a large deviation between the actual storage material position and the storage location of the shelf in real time, which will increase the instability of the stacking and affect the safety of operation.

[0006] In addition, the above-mentioned solution for positioning the storage location also lacks attention to the execution error of the execution end of the palletizer. The execution end of the palletizer is usually constructed by integrating multiple sensors. Even if the measurement accuracy of each individual sensor is very high, the measurement data of multiple sensors may need to be merged or processed in the sensor integration, which may introduce cumulative errors. Over time or during long-term operation, these cumulative errors may cause the positioning execution of the palletizer to deviate from the expected position, which will significantly affect the final stacking positioning accuracy and cause inaccurate positioning of the material stacking position. Summary of the invention

[0007] In view of the above-mentioned shortcomings of the prior art, an object of the present invention is to provide a high-precision palletizer intelligent control system, which effectively compensates for the problem of low palletizing positioning accuracy in the prior art by optimizing the palletizing positioning control.

[0008] The purpose of the present invention can be achieved through the following technical solutions: a high-precision intelligent control system for palletizers, including: a storage location ideal coordinate positioning module, which is used to determine the shelf placement area and establish a three-dimensional rectangular coordinate system in the shelf placement area. At the same time, the storage locations on the shelf are numbered before materials are stacked, and the position information of each storage location is obtained, and then the ideal coordinates of each storage location on the shelf are located based on the established three-dimensional rectangular coordinate system.

[0009] The positioning association detection module is used to set up settlement monitoring equipment on the ground where the shelves are placed, and evenly arrange pressure sensors on the shelves, so as to detect the ground settlement of the shelves and the uniformity of the shelf load distribution in real time during the material stacking process.

[0010] The scanning, positioning and judging module is used to set the current storage location to be stacked as the target storage location in real time during the material stacking process, and then perform scanning, positioning and judging based on the ground settlement of the ground where the shelf is placed and the uniform distribution of the shelf load before stacking at the target storage location.

[0011] The target storage location scanning module is used to scan the target storage location using the visual sensor installed on the palletizer execution terminal to obtain a scanned image when it is judged that scanning positioning is required, and then capture the feature points of the scanned image to obtain the pixel coordinates of the feature points.

[0012] The target storage location actual coordinate recognition module is used to calibrate the visual sensor, based on which the pixel coordinates of the feature points in the target storage location are converted, and after the conversion, they are aligned with the established rectangular coordinate system to obtain the actual coordinates of the target storage location.

[0013] The positioning deviation analysis module is used to retrieve the ideal coordinates of the target storage location, compare them with the actual coordinates of the target storage location, and analyze the positioning deviation distance of the target storage location.

[0014] The execution deviation analysis module is used to extract the positioning coordinates of the control input and the execution coordinates of the execution terminal from the historical execution records of the palletizer to analyze the execution deviation distance of the palletizer.

[0015] The positioning control module is used to feed back the positioning deviation distance of the target storage location and the execution deviation distance of the palletizer to the control system for positioning control of material transportation to the target storage location.

[0016] The positioning deviation tracing module is used to summarize the storage locations with positioning deviations after the shelf stacking is completed as abnormal storage locations, and to retrieve the ground settlement conditions of the ground where the shelves are placed and the uniform distribution of shelf loads when stacking at the abnormal storage locations, thereby tracing the positioning deviations.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) The present invention obtains the ideal coordinates of each storage location on the shelf by constructing a coordinate system, and uses a visual sensor to perform feature scanning on the storage location to be stacked to obtain the actual coordinates of the storage location to be stacked. At the same time, the positioning coordinates based on the control input and the execution coordinates of the execution terminal in the historical execution record of the palletizer are retrieved to obtain the execution deviation of the palletizer. Thus, the actual coordinates of the storage location to be stacked and the ideal coordinates and the execution deviation of the palletizer are used for positioning control, thereby realizing high-precision positioning control of palletizing based on machine vision, greatly improving the accuracy and reliability of material stacking, which is beneficial to improving the stability of stacking and minimizing the risk of material falling.

[0018] (2) The present invention takes into account that the main factors causing the deviation between the actual coordinates of the storage location and the ideal coordinates are ground subsidence and uneven distribution of shelf loads. Therefore, ground subsidence and shelf load distribution are detected in real time during the material stacking process, and then the need for using machine vision for scanning and positioning is judged based on the detection results. Scanning and positioning can be triggered according to the judgment results, which can avoid unnecessary frequent scanning and positioning operations, save resources and energy consumption, and realize the effective use of scanning and positioning.

[0019] (3) After the shelf stacking is completed, the present invention adds a storage location that summarizes the deviation between the actual coordinates and the ideal coordinates, and retrieves the ground settlement of the ground where the shelf is placed and the uniformity of the shelf load distribution when stacking at the storage location. The positioning deviation is traced to the source, and the tendency factors that cause positioning errors can be deeply understood. Targeted adjustment directions are provided for the shelf placement area and shelf structure adjustment, thereby achieving effective improvements in future stacking operations. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for describing the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0021] Figure 1 It is a schematic diagram of the connection of each module of the system of the present invention.

[0022] Figure 2 A schematic diagram of establishing a three-dimensional rectangular coordinate system for the shelf placement area in the present invention.

[0023] Figure 3 It is a schematic diagram of the boundary outline of the ground where the shelf placement area is located in the present invention. DETAILED DESCRIPTION

[0024] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0025] like Figure 1 As shown, the present invention proposes a high-precision palletizer intelligent control system, including a storage location ideal coordinate positioning module, a positioning association detection module, a scanning positioning evaluation module connected to the positioning association detection module, a target storage location scanning module connected to the scanning positioning evaluation module, a target storage location actual coordinate identification module connected to the target storage location scanning module, a positioning deviation analysis module connected to both the storage location ideal coordinate positioning module and the target storage location actual coordinate identification module, an execution deviation analysis module, a positioning control module connected to both the positioning deviation analysis module and the execution deviation analysis module, and a positioning deviation tracing module connected to the positioning deviation analysis module.

[0026] The storage location ideal coordinate positioning module is used to determine the shelf placement area and establish a three-dimensional rectangular coordinate system in the shelf placement area. At the same time, the storage locations on the shelf are numbered before the goods are stacked, the location information of each storage location is obtained, and then the ideal coordinates of each storage location on the shelf are located based on the established three-dimensional rectangular coordinate system.

[0027] In particular, since the storage location has a certain spatial volume, the coordinates of the center point of the storage location can be taken as the ideal coordinates of the storage location.

[0028] As a preferred method of the present invention, a three-dimensional rectangular coordinate system is established in the shelf placement area. See the following process: select an inflection point of the floor where the shelf placement area is located as the origin of the coordinate system, and use the length direction, width direction and height direction of the shelf as the horizontal axis, vertical axis and vertical axis, respectively, to establish a three-dimensional rectangular coordinate system, see Figure 2 shown.

[0029] It should be noted that the inflection point mentioned above refers to a corner point of the shelf placement area, ensuring that it is within the coverage range of the shelf.

[0030] What you need to know further is that since most shelves are perpendicular to the ground, and the length and width directions are also perpendicular to each other, the length direction of the shelf is used as the horizontal axis to ensure that all X coordinate values ​​are positive, the width direction of the shelf is used as the vertical axis to ensure that all Y coordinate values ​​are positive, and the height direction of the shelf is used as the vertical axis to ensure that all Z coordinate values ​​are positive. In this way, the coordinates of each shelf storage location are positive, which facilitates subsequent positioning. By combining the length, width, and height characteristics of the shelf to construct a coordinate system, the location information of each storage location on the shelf can be accurately located, and the management and understanding of the coordinates can be simplified.

[0031] Applied to the above embodiment, the storage locations on the shelves can be numbered according to the row and column numbers of the shelves where the storage locations are located. In a specific example, the row of the shelf where the storage location is located is the 5th row and the column is the 3rd column, so the storage location is numbered 53. This numbering can accurately locate each storage location, so that the staff can quickly find the required storage location according to the number without lengthy search, thereby improving work efficiency.

[0032] The positioning association detection module is used to set up settlement monitoring equipment on the ground where the shelf is placed, and evenly arrange pressure sensors on the shelf, so as to detect the ground settlement of the shelf and the uniformity of the shelf load distribution in real time during the cargo stacking process.

[0033] As an innovative implementation of the present invention, a settlement monitoring device is set up on the ground where the shelf placement area is located. The operation is as follows: the boundary contour of the ground where the shelf placement area is located is obtained by obtaining the shape contour of the shelf, see Figure 3 As shown, the turning points are marked on the boundary contour.

[0034] In the above, a laser scanner or other measuring tools can be used to obtain the shape outline of the shelf placement area.

[0035] Furthermore, the boundary outline of the ground where the shelf is placed is generally the outer boundary of the shelf support area, including the bottom support structure of the shelf.

[0036] Furthermore, a turning point of a boundary contour is a corner or a change point of the boundary contour.

[0037] Set up settlement monitoring equipment at the turning point of the boundary contour, where the settlement monitoring equipment can use devices such as inclinometers, inclinometers or displacement sensors, which can measure the inclination angle or displacement of the ground or structural objects relative to a reference surface.

[0038] It should be added that by utilizing the shape contour of the shelf to determine the boundary contour of the ground, and installing settlement monitoring equipment at the turning points of the boundary contour, these points are usually the main concentrated areas of structural deformation and load distribution. This is because the shelves usually have support columns or brackets to support the storage racks. These supporting structures will be centrally arranged and installed at the turning points of the boundary contour. When materials are stacked, the turning points of the shelf boundary contour are often the main areas for load transfer (such as the weight of stored items). Therefore, the ground settlement data obtained at these points are more representative and reliable. Compared with the uniform installation of settlement monitoring equipment on the boundary contour, it may lead to an increase in the number of equipment and increase installation and maintenance costs.

[0039] It is necessary to explain that the settlement monitoring of the ground where the shelves are located is carried out on the one hand because the weight of the goods stored on the shelves will impose additional loads on the ground. If the bearing capacity of the ground is insufficient or the soil of the ground itself is uneven, bearing such heavy loads for a long time may cause ground settlement. On the other hand, if the foundation under the ground is uneven or affected by other factors (such as changes in groundwater levels, geological conditions, etc.), it will cause uneven settlement or weakening of the foundation. At the same time, different types of soil have different compressibility and stability. Some types of soil (such as silt, soft clay, etc.) are prone to compression after being loaded, which will aggravate ground settlement on the basis of heavy loads.

[0040] As another innovative implementation of the present invention, pressure sensors are evenly arranged on the shelves to achieve the following: Count the number of stacking layers of the shelves, where the stacking layers are the number of rows of the shelves.

[0041] The length of the shelf is compared with the preset reference length. If the length of the shelf is less than or equal to the reference length, pressure sensors are placed at both ends of each stacking layer. Otherwise, the detection coverage range of the selected pressure sensor is obtained. The specifications of the pressure sensor are obtained from its instructions for use, thereby determining the length division intervals of the stacking layers.

[0042] Pressure sensors are arranged at equal intervals in each stacking layer according to length.

[0043] It should be understood that when arranging pressure sensors on a shelf, the pressure sensors need to be distributed as evenly as possible to represent the load condition of the entire shelf.

[0044] For shorter shelves, goods are relatively concentrated in the middle area of ​​the shelves. Therefore, placing sensors at both ends of the stacking layer can effectively cover the overall load distribution of the stacking area without having to install sensors at every possible location.

[0045] For longer shelves, the distribution of goods may be uneven, especially in the length direction. The loads borne at different positions may be different. Therefore, laying out multiple pressure sensors can ensure more detailed and comprehensive monitoring of the load distribution on the entire shelf, without ignoring the conditions in other areas due to high loads at local locations. Specifically, when laying out pressure sensors on long shelves, the length division intervals are determined based on the detection coverage range of the pressure sensors. In this way, the optimal position of each sensor can be determined to ensure that it can accurately cover and monitor the load distribution within the specified length, which is conducive to ensuring the accuracy and reliability of the data, while minimizing the number of sensors, thereby saving costs.

[0046] In a more optimized manner, the ground subsidence detection is specifically implemented as follows: the displacement and inclination angle collected by each subsidence monitoring device are compared with the safe displacement and safe inclination angle, and the ground subsidence index of the location where each subsidence monitoring device is set is calculated. The specific calculation expression is: , where , They respectively represent the displacement and tilt angle collected by the settlement monitoring equipment. , Respectively represent the safe displacement and safe tilt angle. Represents a natural constant.

[0047] The displacement extracted above refers to the settlement displacement along the z-axis, and the tilt angle refers to the tilt angle relative to the horizontal plane (i.e., the xoy plane).

[0048] Furthermore, the above-mentioned safe displacement and safe tilt angle can be determined based on geological exploration and structural design characteristics of the shelf.

[0049] The ground settlement index at the location where each settlement monitoring device is set is calculated for the maximum value, and the minimum ground settlement index is selected as the ground settlement condition of the ground where the shelf is placed.

[0050] It should be understood that selecting the minimum ground settlement index as the ground settlement condition of the ground where the shelves are placed can provide a benchmark for subsequently comparing it with the permitted ground settlement index to determine whether scanning and positioning are needed. The minimum ground settlement index provides a benchmark showing the current ground settlement status. By comparing it with the permitted ground settlement index, it can be evaluated whether the current ground settlement condition is within the allowable range. If the minimum index is lower than or close to the permitted value, it indicates that the ground settlement condition is relatively stable and further scanning and positioning may not be required immediately. If the minimum index exceeds the permitted value, it indicates that the values ​​monitored by all settlement monitoring devices set up on the ground where the shelves are placed exceed the permitted values, indicating that the ground settlement is more serious and scanning and positioning is required. In addition, selecting the minimum ground settlement index as the screening benchmark can avoid the need to compare the values ​​monitored by all settlement monitoring devices, which can save cost and time.

[0051] Further optimized, the uniformity of shelf load distribution is specifically detected as follows: extract the pressure value detected by each pressure sensor in each stacking layer of the shelf, and compare the pressure values ​​detected by each pressure sensor in the same stacking layer, and select the maximum pressure value and the minimum pressure value therefrom.

[0052] The maximum pressure value and the minimum pressure value corresponding to each stacking layer are subtracted to obtain the stacking pressure difference corresponding to each stacking layer.

[0053] The stacking pressure differences corresponding to each stacking layer are compared, and the maximum stacking pressure difference and the minimum stacking pressure difference are selected. The maximum stacking pressure difference and the minimum stacking pressure difference are subtracted, and then two-thirds is used as the base, and the difference between the maximum stacking pressure difference and the minimum stacking pressure difference is divided by the maximum stacking pressure difference as an index to obtain the uniformity of shelf load distribution. The smaller the difference between the maximum stacking pressure difference and the minimum stacking pressure difference, the smaller the load difference between the layers and the more uniform the distribution of goods.

[0054] It is necessary to explain that the reason why the load distribution on the shelves is uneven is that, on the one hand, the operators are restricted by the habit of storing and retrieving goods. When controlling the palletizing robot to store and retrieve goods, the operators may be more inclined to use certain areas on certain shelves, while other areas are used less frequently. This may cause the frequently used areas to have heavier loads, while the infrequently used areas to have lighter loads. On the other hand, the types and sizes of goods stored on the shelves are different. Some goods may be larger or heavier, while others may be smaller or lighter. If the storage space is not properly planned and managed, it may cause uneven loads in different parts.

[0055] The scanning, positioning and judging module is used to use the current storage location to be stacked as the target storage location in real time during the goods stacking process, and then perform scanning, positioning and judging based on the ground settlement of the ground where the shelf is placed and the uniformity of the shelf load distribution before stacking at the target storage location. The specific judging process is: comparing the ground settlement index of the ground where the shelf is placed and the uniformity of the shelf load distribution with the set permitted ground settlement index and the effective shelf load distribution uniformity, respectively, wherein the permitted ground settlement index and the effective shelf load distribution uniformity are both initially set by the system, and are specifically provided by the manufacturer based on the design and manufacturing standards of the shelf and the actual needs of goods storage and use. For example, the permitted ground settlement index is 0.3, and the effective shelf load distribution uniformity is 0.7. If the ground settlement index of the ground where the shelf is placed is less than or equal to the permitted ground settlement index and the shelf load distribution uniformity is greater than or equal to the effective shelf load distribution uniformity, then it is judged that scanning and positioning is not required, otherwise it is judged that scanning and positioning is required.

[0056] The target storage location scanning module is used to scan the target storage location using a visual sensor installed on the palletizer execution terminal to obtain a scanned image when it is judged that scanning positioning is required, wherein the visual sensor can be a laser radar or a stereo camera, and then the feature points of the scanned image are captured to obtain the pixel coordinates of the feature points.

[0057] The above-mentioned feature points can be the edge, corner or pre-designed marker (such as barcode, QR code, etc.) of the storage location. The feature points can be captured by edge detection algorithm, corner detection algorithm or marker recognition algorithm based on template matching. The pixel coordinates are the position relative to the origin of the image (usually the upper left corner of the image). The pixel coordinates can be calculated by the pixel resolution of the sensor and the image processing software.

[0058] The target storage location actual coordinate recognition module is used to calibrate the visual sensor, thereby converting the pixel coordinates of the feature points in the target storage location, and aligning them with the established rectangular coordinate system after conversion to obtain the actual coordinates of the target storage location.

[0059] It should be added that the calibration of the visual sensor is the process of determining its internal parameters (such as focal length, principal point position), external parameters (such as position and posture), and lens distortion. The calibration process generates a transformation matrix, which transforms the points in the visual sensor coordinate system into the world coordinate system through mathematical transformation.

[0060] It should be further added that the alignment after conversion with the established rectangular coordinate system to obtain the actual coordinates of the target storage location is to map the world coordinate system converted by the visual sensor to the storage location coordinate system. Commonly used techniques include rotation matrices, translation vectors and possible scaling factors to ensure the correct mapping and alignment of data between different coordinate systems.

[0061] The present invention uses visual sensors to scan storage locations by utilizing advanced calibration techniques and coordinate system alignment methods to reduce or eliminate the effects of ground subsidence and load changes. These technologies ensure that the data captured by the visual sensors is consistent with the actual storage location.

[0062] The positioning deviation analysis module is used to retrieve the ideal coordinates of the target storage location and compare them with the actual coordinates of the target storage location to analyze the positioning deviation distance of the target storage location. The specific analysis is as follows: the actual coordinates of the target storage location are compared with the ideal coordinates to obtain the positioning coordinate difference corresponding to each coordinate axis;

[0063] The absolute value of the positioning coordinate difference corresponding to each coordinate axis is calculated and then averaged to obtain the positioning deviation distance of the target storage location.

[0064] It should be added that the calculation of the positioning deviation distance in the above-mentioned method adopts the calculation method of the average value of the absolute difference of the coordinate axes. This deviation distance reflects the average absolute difference between the actual coordinates and the ideal coordinates on each coordinate axis, which can more accurately understand the problems in the positioning process. Since the analysis of the positioning deviation distance is used for subsequent positioning control, this calculation method can provide more direct control information and facilitate positioning control.

[0065] The execution deviation analysis module is used to extract the positioning coordinates of the control input and the execution coordinates of the execution terminal from the historical execution records of the palletizer to analyze the execution deviation distance of the palletizer.

[0066] The above historical execution records are recorded by the control system of the palletizer to record the control input positioning coordinates of each execution instruction. During the execution of the instruction, the execution terminal (such as the end of the robot arm, the gripper, etc.) will perform actions according to the control input, and use the built-in sensor to provide real-time feedback on the actual positioning coordinates of the execution terminal, thus forming a historical execution record.

[0067] Optimally, the positioning coordinates of the control input in each historical execution record are compared with the execution coordinates of the execution terminal to obtain the execution coordinate difference corresponding to each coordinate axis.

[0068] The execution time corresponding to each historical execution record is extracted, and a two-dimensional coordinate system is constructed with the execution time as the horizontal coordinate and the execution coordinate difference corresponding to each coordinate axis as the vertical coordinate. Thus, several points are marked in the constructed two-dimensional coordinate system for the execution coordinate difference corresponding to each coordinate axis in each historical execution record to form an execution coordinate difference change curve corresponding to each coordinate axis, and the change rate is obtained from the change curve, wherein the change rate of the change curve can be obtained by obtaining the slope of each point in the change curve and calculating the mean thereof.

[0069] The execution coordinate difference values ​​corresponding to each coordinate axis in each historical execution record are averaged, and the calculation result is combined with the change rate of the execution coordinate difference change curve corresponding to the coordinate axis to analyze the effective execution coordinate difference value corresponding to each coordinate axis. Specifically, .

[0070] The effective execution coordinate difference corresponding to each coordinate axis is calculated by absolute value and then averaged to obtain the execution deviation distance of the analysis palletizer.

[0071] It should be noted that the execution deviation distance of the palletizer in the above-mentioned method is also calculated by the average value of the absolute difference of the coordinate axes. However, since the execution deviation distance of the palletizer is analyzed from multiple historical execution records, each historical execution record has execution coordinate difference values ​​corresponding to each coordinate axis. Therefore, the change curve is used to analyze the change trend of the execution coordinate difference values ​​corresponding to each coordinate axis, and then the execution deviation distance of the palletizer is calculated based on the analysis results, which can improve the calculation accuracy and foresight of the execution deviation distance.

[0072] The positioning control module is used to feed back the positioning deviation distance of the target storage location and the execution deviation distance of the palletizer to the control system to perform positioning control for transporting the goods to the target storage location.

[0073] The positioning deviation tracing module is used to summarize the storage locations with positioning deviations after the shelf stacking is completed as abnormal storage locations, and retrieve the ground settlement conditions of the ground where the shelves are placed and the uniformity of the shelf load distribution when stacking at the abnormal storage locations, thereby tracing the positioning deviation. The specific implementation is as follows: the ground settlement index of the ground where the shelves are placed and the shelf load distribution uniformity when stacking at each abnormal storage location are compared with the set permitted ground settlement index and effective shelf load distribution uniformity, respectively, to identify the positioning deviation direction corresponding to each abnormal storage location, wherein when the ground settlement index is greater than the permitted ground settlement index, the positioning deviation direction is ground settlement, and when the shelf load distribution uniformity is less than the effective shelf load distribution uniformity, the positioning deviation direction is uneven shelf load distribution.

[0074] It should be explained that the above-mentioned storage position with positioning deviation refers to the storage position where the positioning deviation distance is greater than the system setting value.

[0075] The positioning deviation directions corresponding to each abnormal storage location are compared, and then the same positioning deviation directions are classified, and the occurrence frequency corresponding to each positioning deviation direction is counted to screen out the positioning deviation tendency.

[0076] Specifically, the occurrence frequency corresponding to ground subsidence can be compared with the occurrence frequency corresponding to uneven shelf load distribution. If the occurrence frequency corresponding to ground subsidence is higher than the occurrence frequency corresponding to uneven shelf load distribution, the positioning deviation tends to be ground subsidence. If the occurrence frequency corresponding to ground subsidence is lower than the occurrence frequency corresponding to uneven shelf load distribution, the positioning deviation tends to be uneven shelf load distribution. If the two are equal, the positioning deviation tends to be both ground subsidence and uneven shelf load distribution.

[0077] The present invention adds a storage location that summarizes the deviation between the actual coordinates and the ideal coordinates after the shelf stacking is completed, and retrieves the ground settlement of the ground where the shelf is placed and the uniformity of the shelf load distribution when stacking in the storage location, thereby tracing the positioning deviation, and gaining an in-depth understanding of the tendency factors that cause positioning errors, providing targeted adjustment directions for the shelf placement area and shelf structure adjustment, thereby achieving effective improvement in future stacking operations.

[0078] The above contents are merely examples and explanations of the concept of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the concept of the invention or exceed the scope defined by the present invention, they shall all fall within the protection scope of the present invention.

Claims

1. A high-precision palletizer intelligent control system, characterized in that ,include: The storage location ideal coordinate positioning module is used to determine the shelf placement area and establish a three-dimensional rectangular coordinate system in the shelf placement area. At the same time, the storage locations on the shelf are numbered before the materials are stacked, and the location information of each storage location is obtained, and then the ideal coordinates of each storage location on the shelf are located based on the established three-dimensional rectangular coordinate system; The positioning association detection module is used to set up settlement monitoring equipment on the ground where the shelves are placed, and evenly arrange pressure sensors on the shelves, so as to detect the ground settlement of the shelves and the uniformity of the shelf load distribution in real time during the material stacking process; The scanning and positioning evaluation module is used to take the current storage location to be stacked as the target storage location in real time during the material stacking process, and then perform scanning and positioning evaluation based on the ground settlement of the shelf placement and the uniform distribution of shelf load before stacking at the target storage location; The target storage location scanning module is used to scan the target storage location using the visual sensor installed on the palletizer execution terminal to obtain a scanned image when it is judged that scanning positioning is required, and then capture the feature points of the scanned image to obtain the pixel coordinates of the feature points; The target storage location actual coordinate recognition module is used to calibrate the visual sensor, based on which the pixel coordinates of the feature points in the target storage location are converted, and after the conversion, they are aligned with the established rectangular coordinate system to obtain the actual coordinates of the target storage location; Positioning deviation analysis module, used to retrieve the ideal coordinates of the target storage location, compare them with the actual coordinates of the target storage location, and analyze the positioning deviation distance of the target storage location; An execution deviation analysis module is used to extract the positioning coordinates of the control input and the execution coordinates of the execution terminal from the historical execution records of the palletizer to analyze the execution deviation distance of the palletizer; The positioning control module is used to feed back the positioning deviation distance of the target storage location and the execution deviation distance of the palletizer to the control system for positioning control of material transportation to the target storage location.

2. A high-precision palletizer intelligent control system as claimed in claim 1, characterized in that: The process of establishing a three-dimensional rectangular coordinate system in the shelf placement area is as follows: An inflection point of the ground where the shelf is placed is selected as the origin of the coordinate system, and the length, width and height directions of the shelf are used as the horizontal axis, longitudinal axis and vertical axis respectively, thereby establishing a three-dimensional rectangular coordinate system.

3. A high-precision palletizer intelligent control system as claimed in claim 1, characterized in that: The operation of setting up the settlement monitoring equipment on the ground where the shelf is placed is as follows: The boundary contour of the ground where the shelf is placed is obtained by obtaining the shape contour of the shelf, and then the turning points are marked on the boundary contour; Set up settlement monitoring equipment at the turning points of the boundary contour.

4. The high-precision palletizer intelligent control system according to claim 1, characterized in that: The uniform arrangement of pressure sensors on the shelves is achieved as follows: Count the number of stacking layers on the shelf; Compare the length of the shelf with the preset reference length. If the length of the shelf is less than or equal to the reference length, pressure sensors are placed at both ends of each stacking layer. Otherwise, the detection coverage of the selected pressure sensor is obtained to determine the length division interval of the stacking layer. Pressure sensors are arranged at equal intervals in each stacking layer according to length.

5. The high-precision palletizer intelligent control system according to claim 1, characterized in that: The ground subsidence detection is specifically implemented as follows: Compare the displacement and inclination angle collected by each settlement monitoring device with the safe displacement and safe inclination angle, and calculate the ground settlement index at the location where each settlement monitoring device is set. The specific calculation expression is: , where , They respectively represent the displacement and tilt angle collected by the settlement monitoring equipment. , Respectively represent the safe displacement and safe tilt angle. represents a natural constant; The ground settlement index at the location where each settlement monitoring device is set is calculated for the maximum value, and the minimum ground settlement index is selected as the ground settlement condition of the ground where the shelf is placed.

6. A high-precision palletizer intelligent control system as claimed in claim 5, characterized in that: The specific detection of the uniform distribution of the shelf load is as follows: Extract the pressure values ​​detected by each pressure sensor in each stacking layer of the shelf, and compare the pressure values ​​detected by each pressure sensor in the same stacking layer, and select the maximum pressure value and the minimum pressure value; Subtract the maximum pressure value and the minimum pressure value corresponding to each stacking layer to obtain the stacking pressure difference corresponding to each stacking layer; The stacking pressure differences corresponding to each stacking layer are compared, and the maximum stacking pressure difference and the minimum stacking pressure difference are selected. The maximum stacking pressure difference and the minimum stacking pressure difference are subtracted, and then two-thirds is used as the base, and the difference between the maximum stacking pressure difference and the minimum stacking pressure difference is divided by the maximum stacking pressure difference as the index to obtain the uniformity of shelf load distribution.

7. A high-precision palletizer intelligent control system as claimed in claim 6, characterized in that: The scanning positioning evaluation is performed as follows: The ground settlement index of the ground where the shelf is placed and the shelf load distribution uniformity are compared with the set permitted ground settlement index and effective shelf load distribution uniformity respectively. If the ground settlement index of the ground where the shelf is placed is less than or equal to the permitted ground settlement index and the shelf load distribution uniformity is greater than or equal to the effective shelf load distribution uniformity, it is judged that scanning and positioning is not required, otherwise scanning and positioning is required.

8. The high-precision palletizer intelligent control system according to claim 1, characterized in that: The positioning deviation distance of the target storage location is analyzed as follows: Compare the actual coordinates of the target storage location with the ideal coordinates to obtain the positioning coordinate difference corresponding to each coordinate axis; The absolute value of the positioning coordinate difference corresponding to each coordinate axis is calculated and then averaged to obtain the positioning deviation distance of the target storage location.

9. The high-precision palletizer intelligent control system according to claim 1, characterized in that: The analysis palletizer performs deviation distance operations as follows: Compare the positioning coordinates of the control input in each historical execution record with the execution coordinates of the execution terminal to obtain the execution coordinate difference corresponding to each coordinate axis; Extract the execution time corresponding to each historical execution record, and construct a two-dimensional coordinate system with the execution time as the horizontal coordinate and the execution coordinate difference corresponding to each coordinate axis as the vertical coordinate. Then, mark several points in the constructed two-dimensional coordinate system according to the execution coordinate difference corresponding to each coordinate axis in each historical execution record, form an execution coordinate difference change curve corresponding to each coordinate axis, and obtain the change rate from the change curve; The execution coordinate difference values ​​corresponding to each coordinate axis in each historical execution record are averaged, and the calculation result is combined with the change rate of the execution coordinate difference change curve corresponding to the coordinate axis to analyze the effective execution coordinate difference value corresponding to each coordinate axis; The effective execution coordinate difference corresponding to each coordinate axis is calculated by absolute value and then averaged to obtain the execution deviation distance of the analysis palletizer.

10. The high-precision palletizer intelligent control system according to claim 7, characterized in that: It also includes a positioning deviation tracing module, which is used to summarize the storage locations with positioning deviations after the shelf stacking is completed as abnormal storage locations, and retrieve the ground settlement of the ground where the shelves are placed and the uniform distribution of shelf loads when stacking at abnormal storage locations, thereby tracing the positioning deviations. The specific implementation is as follows: The ground settlement index of the ground on which the shelves are placed and the shelf load distribution uniformity when stacking at each abnormal storage location are compared with the set allowable ground settlement index and effective shelf load distribution uniformity, thereby identifying the positioning deviation direction corresponding to each abnormal storage location; The positioning deviation directions corresponding to each abnormal storage location are compared, and then the same positioning deviation directions are classified, and the occurrence frequency corresponding to each positioning deviation direction is counted to screen out the positioning deviation tendency.

Images