A method and system for sorting and mixing rectangular materials

Abstract

The present invention relates to the field of intelligent sorting and palletizing technology, and in particular to a method and system for follow-up sorting and mixed palletizing of rectangular materials, the method comprising: obtaining information of a number of actual rectangular materials; analyzing and classifying the information of a number of actual rectangular materials, and obtaining classification results; determining a preset palletizing strategy based on palletizing tray information and sorting results; identifying whether a target rectangular material meets a preset grabbing condition, and grabbing or grabbing the next time based on the recognition result; calculating a preset palletizing position based on the target material information and a three-dimensional packing algorithm; generating a target rectangular material model based on the target material information, generating a preview palletizing model based on the target rectangular material model and the preset palletizing position, analyzing the preview palletizing model and judging the dumping risk, and adjusting the preset palletizing position based on the dumping risk; analyzing the actual palletizing layout of the palletizing tray, and determining whether the material sorting and mixed palletizing is completed based on the analysis result. The present invention improves the efficiency of the palletizing process.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent sorting and palletizing, and in particular to a method and system for follow-up sorting and mixed palletizing of rectangular materials. Background Art

[0002] With the development of industry, intelligent equipment has been widely used in manufacturing, warehousing and logistics industries, saving a lot of manpower for enterprises, improving production efficiency and reducing production costs. An important link in the field of manufacturing and warehousing logistics is the palletizing of goods, especially for a large number of box-type packaging goods. Using manpower to palletize goods not only greatly increases the manpower cost of enterprises, but also increases the health risks of personnel.

[0003] The patent document with Chinese patent application number CN110681614A discloses a palletizing robot sorting device based on computer vision, including a camera and a conveying platform. The conveying platform includes conveying rollers and conveying belts. The conveying belts are wrapped around the outside of the conveying rollers. A loading turntable is provided on one side of the conveying platform. Products to be palletized are placed on the loading turntable. A sliding platform is installed between the conveying platform and the loading turntable. The camera is installed directly above the conveying platform. The conveying platform is provided with processing points, stacking points and interception points.

[0004] When the existing sorting and palletizing equipment in the industry sorts and palletizes rectangular items, it can only realize the palletizing of items of a single rectangular size, and cannot realize the mixed sorting and palletizing of items of multiple specifications and sizes, thus affecting the efficiency of palletizing. Summary of the invention

[0005] To this end, the present invention provides a rectangular material follow-up sorting mixed stacking method and system, which can solve the problem of low efficiency in the stacking process.

[0006] To achieve the above object, the present invention provides a method for moving sorting and mixed palletizing of rectangular materials, the method comprising:

[0007] Detecting a number of actual rectangular materials on the conveyor belt, and obtaining information of the actual rectangular materials according to the detection results;

[0008] Analyze the actual rectangular material information of the plurality of materials, draw a material information graph based on the material information analysis result, classify the actual rectangular materials according to the material information graph analysis result, and obtain a material classification result;

[0009] Based on the classification results, the plurality of actual rectangular materials are sorted and transmitted to the first circulation buffer line or the second circulation buffer line respectively, the actual rectangular materials in the first circulation buffer line and the second circulation buffer line are sorted respectively, and the preset palletizing strategy is determined based on the palletizing tray information and the sorting results;

[0010] Determine the target rectangular material based on the preset stacking strategy, identify whether the target rectangular material meets the preset grabbing condition through the visual detection device, if it meets the preset grabbing condition, place the target rectangular material in the stacking tray through the grabbing mechanism and adjust the stacking position accordingly, if it does not meet the preset grabbing condition, the target rectangular material continues to circulate in the circulation buffer line;

[0011] Calculating a preset stacking position of the target rectangular material based on target material information corresponding to the target rectangular material and a three-dimensional packing algorithm;

[0012] Generate a target rectangular material model based on the target material information, generate a preview palletizing model based on the target rectangular material model and the preset palletizing position, analyze the preview palletizing model, determine the dumping risk based on the analysis result, adjust the preset palletizing position based on the dumping risk, and obtain the adjusted palletizing position;

[0013] The actual palletizing layout of the palletizing tray is analyzed, and whether the material palletizing is completed is determined based on the analysis result.

[0014] Furthermore, the step of obtaining information of a plurality of actual rectangular materials according to the detection results includes:

[0015] Reading the RFID tag on any of the actual rectangular materials based on an RFID reader / writer, and obtaining actual weight information, actual compression resistance information, and initial size information based on the reading result;

[0016] The image of the actual rectangular material is identified based on image detection technology, so as to analyze the image to obtain image size information, to verify the initial size information according to the image, and to determine the actual size information according to the verification result.

[0017] Furthermore, the step of drawing a material information graph based on the material information analysis result includes:

[0018] Determine the volume information of the actual rectangular material based on the actual size information;

[0019] Standardizing the volume information, the actual weight information, and the actual compression resistance information respectively;

[0020] The standardized volume information, the actual weight information and the actual pressure resistance information are mapped in a blank preset circular graph to generate a material information graph.

[0021] Furthermore, the step of classifying the plurality of actual rectangular materials according to the analysis result of the material information graph includes:

[0022] Calculate the proportion of the material information area in the material information graph as the actual proportion;

[0023] The actual proportion is compared with the preset proportion. When the actual proportion is greater than the preset proportion, the actual material is classified as lower-layer material. When the actual proportion is less than or equal to the preset proportion, the actual material is classified as middle-upper-layer material.

[0024] Furthermore, the step of determining a preset palletizing strategy based on the palletizing tray information includes:

[0025] Determining the size information and load-bearing information of the pallet;

[0026] Determine the maximum total weight of the placed materials based on the load-bearing information;

[0027] Determine the maximum placement area and maximum placement height for placing the material based on the size information;

[0028] The preset palletizing strategy is determined based on the maximum total weight, the maximum placement area, the maximum placement height and the sorting result.

[0029] Furthermore, the step of identifying whether the target rectangular material meets the preset grasping conditions by a visual detection device includes:

[0030] Capturing a real-time image of the target rectangular material through a visual inspection device;

[0031] Identify the target rectangular material image in the real-time image by using an image segmentation algorithm;

[0032] Matching the target rectangular material image with a preset material image to obtain an image matching result;

[0033] If the image matching results are the same, identifying the actual posture in the target rectangular material image, comparing the actual posture with the preset posture, and obtaining a posture comparison result;

[0034] If the posture comparison results are the same, then the target rectangular material meets the preset grasping condition.

[0035] Furthermore, the step of calculating the preset stacking position of the target rectangular material based on the target material information corresponding to the target rectangular material and the three-dimensional packing algorithm includes:

[0036] Obtaining the actual length, width and height of the target rectangular material;

[0037] Performing spatial calculation using the three-dimensional packing algorithm according to the actual length value, the actual width value, the actual height value and the current spatial layout in the pallet;

[0038] The preset stacking position is determined based on the spatial calculation result.

[0039] Furthermore, the step of determining the dumping risk based on the analysis result includes:

[0040] Identify and calculate the contact area and the number of supporting points between the target rectangular material and surrounding materials;

[0041] The dumping risk of the target rectangular material is determined based on the contact area and the number of support points.

[0042] Furthermore, the step of analyzing the actual palletizing layout of the palletizing tray comprises:

[0043] Acquire an actual three-dimensional image of the pallet;

[0044] Processing the three-dimensional image by an image recognition algorithm to extract material distribution information in the pallet;

[0045] Calculate actual stability based on the material distribution information to obtain a stability result;

[0046] Whether material palletizing is completed is determined based on the stability result.

[0047] On the other hand, the present invention also provides a rectangular material follow-up sorting and mixed stacking system, the system comprising:

[0048] A detection module is used to detect a number of actual rectangular materials on the conveyor belt and obtain information of the actual rectangular materials according to the detection results;

[0049] A classification module, connected to the detection module, for analyzing the actual rectangular material information, drawing a material information map based on the material information analysis result, classifying the actual rectangular materials according to the material information map analysis result, and obtaining a material classification result;

[0050] A strategy determination module, connected to the classification module, for sorting and transmitting a plurality of the actual rectangular materials to the first circulation buffer line or the second circulation buffer line respectively based on the classification result, sorting the actual rectangular materials in the first circulation buffer line and the second circulation buffer line respectively, and determining a preset palletizing strategy based on the palletizing tray information and the sorting result;

[0051] A judgment module, connected to the strategy determination module, for determining a target rectangular material based on a preset stacking strategy, identifying whether the target rectangular material meets a preset grabbing condition through a visual detection device, and if so, placing the target rectangular material in a stacking tray through a grabbing mechanism and adjusting the stacking position accordingly, and if not, the target rectangular material continues to circulate in the circulation buffer line;

[0052] A calculation module, connected to the judgment module, for calculating a preset stacking position of the target rectangular material based on the target material information corresponding to the target rectangular material and a three-dimensional packing algorithm;

[0053] an adjustment module, connected to the calculation module, for generating a target rectangular material model based on the target material information, generating a preview palletizing model based on the target rectangular material model and the preset palletizing position, analyzing the preview palletizing model, determining the dumping risk based on the analysis result, adjusting the preset palletizing position based on the dumping risk, and acquiring the adjusted palletizing position;

[0054] The palletizing determination module is connected to the adjustment module and is used to analyze the actual palletizing layout of the palletizing tray and determine whether the material palletizing is completed based on the analysis result.

[0055] Compared with the prior art, the beneficial effect of the present invention is that, by detecting and analyzing the actual rectangular materials on the conveyor belt, the material information can be quickly obtained and the material information map can be drawn, thereby realizing the rapid classification of the materials, and significantly improving the efficiency of material processing. According to the classification results of the materials, combined with the pallet information and the sorting results, a more reasonable palletizing strategy is formulated to ensure that the distribution of the materials in the pallet is more uniform and stable, thereby improving the palletizing quality. The visual detection device is used to identify whether the target rectangular material meets the preset grasping conditions, and intelligent grasping is realized to ensure that only qualified materials are palletized, thereby avoiding palletizing failures caused by problems such as poor material quality or inconsistent shapes. In the palletizing process, the preset palletizing position of the target rectangular material is calculated by a three-dimensional packing algorithm, and a preview palletizing model is generated based on the target material information. By analyzing the preview palletizing model, the dumping risk of the material is judged, and the palletizing position is adjusted accordingly, which significantly reduces the dumping risk of the material in the palletizing process, and ensures the safety and stability of the palletizing process. In the palletizing process, the actual palletizing layout of the pallet is monitored and analyzed in real time to ensure the efficiency and accuracy of the entire palletizing process.

[0056] In particular, by comparing the proportion of the material information area in the material information diagram with the preset proportion, the materials can be clearly divided into lower-layer materials and middle-upper-layer materials, which is convenient for subsequent targeted processing or management of the materials. When calculating the proportion of the material information area, the standardized volume information, actual weight information and actual compressive strength information are comprehensively considered to more comprehensively and accurately reflect the overall performance of the materials, avoiding the influence of a single attribute on the classification results. Dividing materials into lower-layer materials and middle-upper-layer materials helps to optimize resource allocation and improve subsequent palletizing efficiency.

[0057] In particular, ensuring that the capacity of the pallet is fully utilized during the palletizing process based on the size information and load-bearing information of the palletizing pallet helps to improve the efficiency and stability of palletizing; palletizing according to the pre-sorting results ensures that the placement order of materials in the palletizing pallet meets the predetermined priority or requirements, which helps to improve the palletizing efficiency; giving priority to stacking materials in the first circulation buffer line helps to ensure that the lower layer materials are given priority processing and improve the stability of palletizing; when the materials in the first circulation buffer line cannot meet the requirements of the palletizing pallet, the materials in the second circulation buffer line are selected for palletizing, which makes full use of the palletizing space, reduces the risk of material dumping and improves the safety of palletizing.

[0058] In particular, by using the three-dimensional packing algorithm, the optimal stacking position of the material in the pallet can be accurately calculated according to the actual size of the target rectangular material and the current spatial layout in the pallet, which helps to maximize the use of the space in the pallet, reduce space waste, and improve overall space utilization. The three-dimensional packing algorithm can build a stable and compact stacking structure in the pallet based on the size and shape of the material, which helps to reduce the movement and damage of the material during transportation and storage, and can also improve the overall stability of the pallet. By applying the three-dimensional packing algorithm, the automatic calculation and optimization of material stacking is realized, thereby improving the stacking efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] Figure 1 A schematic diagram of the flow chart of the method for dynamic sorting and mixed palletizing of rectangular materials provided by an embodiment of the present invention;

[0060] Figure 2 A material information diagram of a rectangular material follow-up sorting and mixed stacking method provided by an embodiment of the present invention;

[0061] Figure 3 A schematic diagram of a process for determining a preset stacking position in a rectangular material follow-up sorting and mixed stacking method provided in an embodiment of the present invention;

[0062] Figure 4 This is a structural block diagram of a rectangular material follow-up sorting and mixed stacking system provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0063] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0064] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the protection scope of the present invention.

[0065] It should be noted that, in the description of the present invention, terms such as "up", "down", "left", "right", "inside" and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the drawings. This is merely for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be understood as a limitation on the present invention.

[0066] In addition, it should be noted that in the description of the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected" and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be the internal communication of two components. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0067] See also Figure 1 As shown, an embodiment of the present invention provides a method for moving sorting and mixed palletizing of rectangular materials, the method comprising:

[0068] Step S100, detecting a number of actual rectangular materials on the conveyor belt, and obtaining information of the number of actual rectangular materials according to the detection results;

[0069] Step S200, analyzing the actual rectangular material information of the plurality of materials, drawing a material information graph based on the material information analysis result, classifying the actual rectangular materials according to the material information graph analysis result, and obtaining a material classification result;

[0070] Step S300, based on the classification result, a plurality of the actual rectangular materials are sorted and transmitted to the first circulation buffer line or the second circulation buffer line, the actual rectangular materials in the first circulation buffer line and the second circulation buffer line are sorted respectively, and a preset palletizing strategy is determined based on the palletizing tray information and the sorting result;

[0071] Step S400, determining a target rectangular material based on a preset stacking strategy, identifying whether the target rectangular material meets a preset grabbing condition through a visual detection device, and if so, placing the target rectangular material in a stacking tray through a grabbing mechanism and adjusting the stacking position accordingly, and if not, the target rectangular material continues to circulate in the circulation buffer line;

[0072] Step S500, calculating a preset stacking position of the target rectangular material based on the target material information corresponding to the target rectangular material and a three-dimensional packing algorithm;

[0073] Step S600, generating a target rectangular material model based on the target material information, generating a preview palletizing model based on the target rectangular material model and the preset palletizing position, analyzing the preview palletizing model, determining the dumping risk based on the analysis result, adjusting the preset palletizing position based on the dumping risk, and acquiring the adjusted palletizing position;

[0074] Step S700, analyzing the actual palletizing layout of the palletizing tray, and determining whether material palletizing is completed based on the analysis result.

[0075] Specifically, the embodiment of the present invention can quickly obtain material information and draw a material information map by detecting and analyzing the actual rectangular materials on the conveyor belt, thereby realizing rapid classification of materials, and significantly improving the efficiency of material processing. According to the classification results of the materials, combined with the pallet information and the sorting results, a more reasonable palletizing strategy is formulated to ensure that the distribution of materials in the pallet is more uniform and stable, thereby improving the palletizing quality. The visual detection device is used to identify whether the target rectangular material meets the preset grasping conditions, and intelligent grasping is realized to ensure that only qualified materials are palletized, avoiding palletizing failures caused by problems such as poor material quality or inconsistent shapes. During the palletizing process, the preset palletizing position of the target rectangular material is calculated by a three-dimensional packing algorithm, and a preview palletizing model is generated based on the target material information. By analyzing the preview palletizing model, the risk of material tipping is judged, and the palletizing position is adjusted accordingly, which significantly reduces the risk of material tipping during the palletizing process and ensures the safety and stability of the palletizing process. During the palletizing process, the actual palletizing layout of the pallet is monitored and analyzed in real time to ensure the efficiency and accuracy of the entire palletizing process.

[0076] Specifically, the step of obtaining information of a number of actual rectangular materials according to the detection results includes:

[0077] Reading the RFID tag on any of the actual rectangular materials based on an RFID reader / writer, and obtaining actual weight information, actual compression resistance information, and initial size information based on the reading result;

[0078] The image of the actual rectangular material is identified based on image detection technology, so as to analyze the image to obtain image size information, to verify the initial size information according to the image, and to determine the actual size information according to the verification result.

[0079] Specifically, the step of analyzing an image to obtain image size information in the embodiment of the present invention includes:

[0080] Acquire an actual image of any of the actual materials by an image processing device;

[0081] Performing denoising preprocessing on the actual image;

[0082] Identify edge contour features in the actual image using an edge detection algorithm to obtain the edge contour of the material;

[0083] Determine the ratio of actual size to pixel size;

[0084] Identifying a pixel length, a pixel width, and a pixel height of the edge contour;

[0085] The actual length value, the actual width value and the actual height value are calculated based on the pixel length, the pixel width and the pixel height and the ratio.

[0086] Specifically, the embodiment of the present invention can quickly read the identification information on the material by setting up an RFID reader / writer, thereby improving the efficiency of information acquisition. The image acquisition device can accurately measure the size of the material, efficiently and accurately obtain the complete information of the material, and provide strong support for subsequent sorting and palletizing. The RFID identification information is unique, which realizes the traceability management of the material and improves the security of the material information.

[0087] Specifically, the step of drawing a material information graph based on the material information analysis result includes:

[0088] Determine the volume information of the actual rectangular material based on the actual size information;

[0089] Standardizing the volume information, the actual weight information, and the actual compression resistance information respectively;

[0090] The standardized volume information, the actual weight information and the actual pressure resistance information are mapped in a blank preset circular graph to generate a material information graph.

[0091] See also Figure 2 The figure shows a possible representation of the material information diagram described in the embodiment of the present invention.

[0092] Specifically, the steps of respectively standardizing the volume information, the actual weight information, and the actual pressure resistance information in the embodiment of the present invention include:

[0093] Assume that the actual weight information is W0, the actual compression resistance information is C0, and the actual volume information is V0. Then the normalized actual weight information is W1=(W0-W min ) / (W max -W min ), where W max is the maximum weight value among several actual weight information, W min The minimum weight value among several actual weight information;

[0094] The actual compressive strength information after standardization is C1=(C0-C min ) / (Cmax -C min ), where C max is the maximum compression resistance value among several actual compression resistance information, C min is the minimum compression resistance value among several actual compression resistance information;

[0095] The actual volume information after standardization is V1=(V0-V min ) / (V max -V min ), where V max is the maximum volume value among several volume information, V min It is the minimum volume value among several volume information.

[0096] Specifically, the step of mapping the standardized volume information, the actual weight information, and the actual pressure resistance information in a blank preset circular graph in the embodiment of the present invention includes:

[0097] The preset blank circular graph is evenly divided into three areas, namely, a volume area, a weight area and a pressure resistance area;

[0098] Based on the standardized volume information, the actual weight information and the actual compressive strength information, the areas occupied by the corresponding regions are respectively calculated, and the corresponding areas are marked to obtain the material information map.

[0099] Specifically, the preset circular proportion described in the embodiment of the present invention is a circle with a radius of 1.

[0100] Specifically, the embodiment of the present invention presents the volume, weight and compression resistance information of the material in a graphical manner, making the data intuitive and facilitating quick acquisition of key information from the material information diagram, thereby performing more effective material evaluation, classification or selection, and standardizing the volume, weight and compression resistance information to ensure that different materials are compared on the same scale, eliminating comparison barriers caused by different units or measurement standards, improving the comparability and accuracy of information, and mapping the standardized information to different areas in a preset pie chart, further improving the visualization of the information, and also allowing different attributes to be clearly distinguished in the diagram, which helps to improve the efficiency of subsequent classification.

[0101] Specifically, the step of classifying the plurality of actual rectangular materials according to the analysis result of the material information graph includes:

[0102] Calculate the proportion of the material information area in the material information graph as the actual proportion;

[0103] The actual proportion is compared with the preset proportion. When the actual proportion is greater than the preset proportion, the actual material is classified as lower-layer material. When the actual proportion is less than or equal to the preset proportion, the actual material is classified as middle-upper-layer material.

[0104] Specifically, the preset proportion described in the embodiment of the present invention is 2 / 3.

[0105] Specifically, the embodiment of the present invention calculates the proportion of the material information area by calculating the sum of the areas occupied by the standardized volume information, the actual weight information and the actual pressure resistance information in their corresponding areas, and dividing the sum by the total area of ​​the preset circular blank image to obtain the actual proportion.

[0106] Specifically, the embodiment of the present invention can clearly divide the materials into lower-layer materials and middle-upper-layer materials by comparing the proportion of the material information area in the material information graph with the preset proportion, so as to facilitate the subsequent targeted processing or management of the materials. When calculating the proportion of the material information area, the standardized volume information, actual weight information and actual compressive resistance information are comprehensively considered to more comprehensively and accurately reflect the overall performance of the materials, avoiding the influence of a single attribute on the classification results. Dividing the materials into lower-layer materials and middle-upper-layer materials helps to optimize resource allocation and improve subsequent palletizing efficiency.

[0107] Specifically, the embodiment of the present invention sorts the actual rectangular materials in the first circular buffer line and the second circular buffer line respectively based on the actual proportion from large to small to obtain the sorting result.

[0108] Specifically, the embodiment of the present invention sorts and transmits a plurality of the actual rectangular materials to the first circulation buffer line or the second circulation buffer line based on the classification result, including:

[0109] Transferring the lower layer material to the first circulation buffer line;

[0110] Transferring the middle and upper layer materials to the second circulation buffer line;

[0111] Wherein, the circulating buffer line is a conveying line used for transmitting and caching materials.

[0112] Specifically, the step of determining a preset palletizing strategy based on the palletizing tray information includes:

[0113] Determining the size information and load-bearing information of the pallet;

[0114] Determine the maximum total weight of the placed materials based on the load-bearing information;

[0115] Determine the maximum placement area and maximum placement height for placing materials based on the size information;

[0116] The preset palletizing strategy is determined based on the maximum total weight, the maximum placement area, the maximum placement height and the sorting result.

[0117] Specifically, the preset stacking strategy described in the embodiment of the present invention is to give priority to selecting the actual rectangular materials in the first circular buffer line, and stack them in sequence according to the sorting results to ensure that they do not exceed the maximum total weight, the maximum placement area and the maximum placement height. When the actual rectangular materials placed in the first circular buffer line exceed the stacking tray information and the actual rectangular materials that have been placed do not exceed the stacking tray information, the actual rectangular materials in the second circular buffer line are selected and stacked in sequence according to the sorting results to ensure that they do not exceed the stacking tray information.

[0118] Specifically, the embodiments of the present invention ensure that the capacity of the palletizing tray is fully utilized during the palletizing process based on the size information and load-bearing information of the palletizing tray, which helps to improve the efficiency and stability of palletizing. Palletizing according to the pre-sorting results ensures that the placement order of materials in the palletizing tray meets the predetermined priority or requirements, which helps to improve the palletizing efficiency. Prioritizing the selection of materials in the first circulation buffer line for palletizing helps to ensure that the lower layer materials are given priority processing and improve the stability of palletizing. When the materials in the first circulation buffer line cannot meet the requirements of the palletizing tray, the materials in the second circulation buffer line are selected for palletizing, which makes full use of the palletizing space, reduces the risk of material dumping, and improves the safety of palletizing.

[0119] Specifically, the step of identifying whether the target rectangular material meets the preset grasping conditions by a visual detection device includes:

[0120] Capturing a real-time image of the target rectangular material through a visual inspection device;

[0121] Identify the target rectangular material image in the real-time image by using an image segmentation algorithm;

[0122] Matching the target rectangular material image with a preset material image to obtain an image matching result;

[0123] If the image matching results are the same, identifying the actual posture in the target rectangular material image, comparing the actual posture with the preset posture, and obtaining a posture comparison result;

[0124] If the posture comparison results are the same, then the target rectangular material meets the preset grasping condition.

[0125] Specifically, the preset material images in the embodiment of the present invention are standard material images corresponding to a number of materials;

[0126] For the rectangular material in the embodiment of the present invention, the preset posture requirement may be that the long side of the material should be parallel to the long side of the pallet, and the inclination angle of the material shall not exceed a certain range (such as 5 degrees);

[0127] The preset size requirement is the standard size corresponding to the standard material image.

[0128] Specifically, the embodiment of the present invention uses a visual detection device to capture real-time images, and accurately identifies the target rectangular material image through an image segmentation algorithm, thereby ensuring that the target rectangular material is accurately identified and located, and matches the target rectangular material image with the preset material image, thereby improving the accuracy and reliability of identification and reducing the possibility of misidentification. After the image matching is successful, it is further determined whether the posture and size of the target rectangular material meet the preset requirements, thereby achieving double verification of the material placement status, ensuring the stability and safety of the material during the stacking process, and optimizing the stacking process by ensuring that the target rectangular material meets the preset grasping conditions, reducing stacking errors or adjustment time caused by material posture or size not meeting the requirements, improving the stacking efficiency, ensuring the stability of the stacking pile, and reducing the risk of material damage.

[0129] See also Figure 3 As shown, the step of calculating the preset stacking position of the target rectangular material based on the target material information corresponding to the target rectangular material and the three-dimensional packing algorithm includes:

[0130] Step S510, obtaining the actual length value, actual width value and actual height value of the target rectangular material;

[0131] Step S520, performing space calculation using the three-dimensional packing algorithm according to the actual length value, the actual width value, the actual height value and the current space layout in the pallet;

[0132] Step S530, determining the preset stacking position based on the spatial calculation result.

[0133] Specifically, the three-dimensional packing algorithm in the embodiment of the present invention may be a first fit descending algorithm (FFD), a best fit descending algorithm (BFD), etc., to quickly find the best stacking position of the target rectangular material in the pallet.

[0134] Specifically, the embodiment of the present invention uses a three-dimensional packing algorithm to accurately calculate the optimal stacking position of the material in the pallet according to the actual size of the target rectangular material and the current spatial layout in the pallet, which helps to maximize the use of the space of the pallet, reduce space waste, and improve the overall space utilization. The three-dimensional packing algorithm can construct a stable and compact stacking structure in the pallet based on the size and shape of the material, which is beneficial to reduce the movement and damage of the material during transportation and storage, and can also improve the overall stability of the pallet. By applying the three-dimensional packing algorithm, automatic calculation and optimization of material stacking are realized, thereby improving the stacking efficiency.

[0135] Specifically, the three-dimensional packing algorithms mentioned in the embodiments of the present invention, such as the first fit decreasing algorithm (FFD) and the best fit decreasing algorithm (BFD), are flexibly selected according to actual needs and material characteristics to achieve the best stacking effect, so that the three-dimensional packing algorithm can quickly find the best stacking position of the target rectangular material in the stacking tray, shorten the calculation time, improve the real-time performance and response speed of the algorithm, and make the material stacking process more efficient and accurate.

[0136] Specifically, the step of determining the dumping risk based on the analysis results includes:

[0137] Identify and calculate the contact area and the number of supporting points between the target rectangular material and surrounding materials;

[0138] The dumping risk of the target rectangular material is determined based on the contact area and the number of support points.

[0139] Specifically, the step of identifying and calculating the contact area and the number of supporting points between the target rectangular material and the surrounding materials in the embodiment of the present invention includes:

[0140] Traverse and obtain the position information of all materials in the preview palletizing model, calculate the distance between the position information and the preset position, and regard the materials with a distance value less than the preset distance value as adjacent materials;

[0141] Identify the contact boundary between the target rectangular material and the adjacent material, and calculate the contact area based on the boundary information;

[0142] Support points are determined on the contact boundary and counted to obtain the number of support points.

[0143] Specifically, the embodiment of the present invention identifies the contact boundary between the target rectangular material and the adjacent material and calculates the contact area, including:

[0144] Determine the geometric relationship by comparing the shape relationship and position relationship between the target rectangular material and the adjacent material;

[0145] Analyzing the geometric relationship, and drawing a contact boundary between the target rectangular material and the adjacent material based on the analysis result;

[0146] An area integration algorithm is used to identify the area of ​​a region formed by the contact boundary, and several area areas obtained by calculating several contact boundaries are accumulated to obtain the contact area.

[0147] Specifically, the step of determining the support point on the contact boundary in the embodiment of the present invention includes:

[0148] The force conditions of the points on the contact boundary are analyzed, and the support points are determined based on the analysis results.

[0149] Specifically, the step of adjusting the preset stacking position based on the dumping risk in the embodiment of the present invention includes:

[0150] Determine the instability factors based on the dumping risk identification results;

[0151] An adjustment strategy is formulated based on the unstable factors, and the preset palletizing position is adjusted based on the adjustment strategy.

[0152] Specifically, a possible example of adjusting the preset stacking in an embodiment of the present invention is that the unstable factors may be that the gaps between materials are too large, the support points are insufficient, the material stacking height is too high, etc., and the corresponding adjustment strategy is to adjust the material arrangement, increase the support points, reduce the stacking height, etc. If the support points are insufficient, it is necessary to move the target rectangular material to a position closer to the existing materials, or add additional support structures. If the stacking height is too high, it may be necessary to lower the placement height of the target rectangular material, or change the stacking hierarchy. The preset stacking position is adjusted based on the adjustment strategy.

[0153] Specifically, the step of analyzing the actual palletizing layout of the palletizing tray includes:

[0154] Acquire an actual three-dimensional image of the pallet;

[0155] Processing the three-dimensional image by an image recognition algorithm to extract material distribution information in the pallet;

[0156] Calculate actual stability based on the material distribution information to obtain a stability result;

[0157] Whether material palletizing is completed is determined based on the stability result.

[0158] Specifically, the step of extracting material distribution information in the pallet according to the embodiment of the present invention includes:

[0159] Segmenting different material regions in the actual three-dimensional image by using an image segmentation algorithm;

[0160] Use image recognition technology to identify several material features in the segmented area;

[0161] Determining the material distribution information based on a number of the material characteristics;

[0162] Wherein, the material characteristics include position information and arrangement information.

[0163] Specifically, the step of calculating the actual stability based on the material distribution information in the embodiment of the present invention includes:

[0164] Identify and calculate the contact area and number of support points between materials;

[0165] The actual stability is determined based on the contact area and the number of support points.

[0166] Specifically, the step of determining whether material sorting and mixed palletizing is completed based on the analysis results in the embodiment of the present invention includes:

[0167] When the actual stability is greater than or equal to the preset stability, the material sorting and mixed stacking is completed;

[0168] When the actual stability is less than the preset stability, the material stacking is adjusted so that the actual stability is greater than or equal to the preset stability.

[0169] Specifically, the embodiments of the present invention obtain actual three-dimensional images of the pallet and process these images using an image recognition algorithm to monitor the material distribution in the pallet in real time, ensure the stability and safety of the palletizing, calculate the actual stability based on the material distribution information, accurately evaluate the stability of the pallet, quantify the stability level by identifying the contact area and the number of support points between the materials, and provide an accurate data basis for adjustment. The image segmentation algorithm and image recognition technology accurately segment different material areas in the pallet and identify the characteristics of the materials, which helps to accurately analyze the distribution and stability of the materials and provide an important basis for optimizing the palletizing layout.

[0170] See also Figure 4 As shown, an embodiment of the present invention further provides a system for a rectangular material follow-up sorting and mixed stacking method, the system comprising:

[0171] The detection module 10 is used to detect a number of actual rectangular materials on the conveyor belt and obtain information of the number of actual rectangular materials according to the detection results;

[0172] The classification module 20 is connected to the detection module 10, and is used to analyze the actual rectangular material information, draw a material information map based on the material information analysis result, classify the actual rectangular materials according to the analysis result of the material information map, and obtain the material classification result;

[0173] A strategy determination module 30 is connected to the classification module 20, and is used to sort and transmit a plurality of the actual rectangular materials to the first circulation buffer line or the second circulation buffer line based on the classification result, sort the actual rectangular materials in the first circulation buffer line and the second circulation buffer line respectively, and determine a preset palletizing strategy based on the palletizing tray information and the sorting result;

[0174] A judgment module 40 is connected to the strategy determination module 30, and is used to determine the target rectangular material based on the preset stacking strategy, and identify whether the target rectangular material meets the preset grabbing condition through a visual detection device. If the preset grabbing condition is met, the target rectangular material is placed in the stacking tray through a grabbing mechanism and the stacking position is adjusted accordingly. If the preset grabbing condition is not met, the target rectangular material continues to circulate in the circulation buffer line;

[0175] A calculation module 50, connected to the judgment module 40, for calculating a preset stacking position of the target rectangular material based on the target material information corresponding to the target rectangular material and a three-dimensional packing algorithm;

[0176] an adjustment module 60, connected to the calculation module 50, for generating a target rectangular material model based on the target material information, generating a preview palletizing model based on the target rectangular material model and the preset palletizing position, analyzing the preview palletizing model, determining the dumping risk based on the analysis result, adjusting the preset palletizing position based on the dumping risk, and acquiring the adjusted palletizing position;

[0177] The palletizing determination module 70 is connected to the adjustment module 60 and is used to analyze the actual palletizing layout of the palletizing tray and determine whether the material palletizing is completed based on the analysis result.

[0178] Specifically, the system of the rectangular material follow-up sorting and mixed stacking method provided in the embodiment of the present invention can execute the above-mentioned rectangular material follow-up sorting and mixed stacking method to achieve the same technical effect, which will not be repeated here.

[0179] So far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will fall within the protection scope of the present invention.

[0180] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A method for sorting and stacking rectangular materials, characterized in that: include: Detecting a number of actual rectangular materials on the conveyor belt, and obtaining information of the actual rectangular materials according to the detection results; Analyze the actual rectangular material information of the plurality of materials, draw a material information graph based on the material information analysis result, classify the actual rectangular materials according to the material information graph analysis result, and obtain a material classification result; Based on the classification results, the plurality of actual rectangular materials are sorted and transmitted to the first circulation buffer line or the second circulation buffer line respectively, the actual rectangular materials in the first circulation buffer line and the second circulation buffer line are sorted respectively, and the preset palletizing strategy is determined based on the palletizing tray information and the sorting results; Determine the target rectangular material based on the preset stacking strategy, identify whether the target rectangular material meets the preset grabbing condition through the visual detection device, if it meets the preset grabbing condition, place the target rectangular material in the stacking tray through the grabbing mechanism and adjust the stacking position accordingly, if it does not meet the preset grabbing condition, the target rectangular material continues to circulate in the circulation buffer line; Calculating a preset stacking position of the target rectangular material based on target material information corresponding to the target rectangular material and a three-dimensional packing algorithm; Generate a target rectangular material model based on the target material information, generate a preview palletizing model based on the target rectangular material model and the preset palletizing position, analyze the preview palletizing model, determine the dumping risk based on the analysis result, adjust the preset palletizing position based on the dumping risk, and obtain the adjusted palletizing position; The actual palletizing layout of the palletizing tray is analyzed, and whether the material palletizing is completed is determined based on the analysis result.

2. The rectangular material follow-up sorting and mixed stacking method according to claim 1 is characterized in that: The step of obtaining information of a plurality of actual rectangular materials according to the detection results comprises: Reading the RFID tag on any of the actual rectangular materials based on an RFID reader / writer, and obtaining actual weight information, actual compression resistance information, and initial size information based on the reading result; The image of the actual rectangular material is identified based on image detection technology, so as to analyze the image to obtain image size information, to verify the initial size information according to the image, and to determine the actual size information according to the verification result.

3. The rectangular material follow-up sorting and mixed stacking method according to claim 2 is characterized in that: The step of drawing a material information graph based on the material information analysis result comprises: Determine the volume information of the actual rectangular material based on the actual size information; Standardizing the volume information, the actual weight information, and the actual compression resistance information respectively; The standardized volume information, the actual weight information and the actual pressure resistance information are mapped in a blank preset circular graph to generate a material information graph.

4. The rectangular material follow-up sorting and mixed stacking method according to claim 3 is characterized in that: The step of classifying the plurality of actual rectangular materials according to the analysis result of the material information graph comprises: Calculate the proportion of the material information area in the material information graph as the actual proportion; The actual proportion is compared with the preset proportion. When the actual proportion is greater than the preset proportion, the actual rectangular material is divided into lower layer materials. When the actual proportion is less than or equal to the preset proportion, the actual rectangular material is divided into middle and upper layer materials.

5. The rectangular material follow-up sorting and mixed stacking method according to claim 4 is characterized in that: The step of determining a preset palletizing strategy based on the palletizing tray information comprises: Determining the size information and load-bearing information of the pallet; Determine the maximum total weight of the placed materials based on the load-bearing information; Determine the maximum placement area and maximum placement height for placing the material based on the size information; The preset palletizing strategy is determined based on the maximum total weight, the maximum placement area, the maximum placement height and the sorting result.

6. The rectangular material follow-up sorting and mixed stacking method according to claim 5 is characterized in that: The step of identifying whether the target rectangular material meets the preset grasping conditions by a visual detection device includes: Capturing a real-time image of the target rectangular material through a visual inspection device; Identify the target rectangular material image in the real-time image by using an image segmentation algorithm; Matching the target rectangular material image with a preset material image to obtain an image matching result; If the image matching results are the same, identifying the actual posture in the target rectangular material image, comparing the actual posture with the preset posture, and obtaining a posture comparison result; If the posture comparison results are the same, then the target rectangular material meets the preset grasping condition.

7. The rectangular material follow-up sorting and mixed stacking method according to claim 6 is characterized in that: The step of calculating the preset stacking position of the target rectangular material based on the target material information corresponding to the target rectangular material and the three-dimensional packing algorithm comprises: Obtaining the actual length, width and height of the target rectangular material; Performing spatial calculation using the three-dimensional packing algorithm according to the actual length value, the actual width value, the actual height value and the current spatial layout in the pallet; The preset stacking position is determined based on the spatial calculation result.

8. The rectangular material follow-up sorting and mixed stacking method according to claim 7 is characterized in that: The step of determining the dumping risk based on the analysis result comprises: Identify and calculate the contact area and the number of supporting points between the target rectangular material and surrounding materials; The dumping risk of the target rectangular material is determined based on the contact area and the number of support points.

9. The rectangular material follow-up sorting and mixed stacking method according to claim 8 is characterized in that: The step of analyzing the actual palletizing layout of the palletizing tray comprises: Acquire an actual three-dimensional image of the pallet; Processing the three-dimensional image by an image recognition algorithm to extract material distribution information in the pallet; Calculate actual stability based on the material distribution information to obtain a stability result; Whether material palletizing is completed is determined based on the stability result.

10. A system using the rectangular material follow-up sorting and mixed stacking method as described in any one of claims 1 to 9, characterized in that: include: A detection module is used to detect a number of actual rectangular materials on the conveyor belt and obtain information of the actual rectangular materials according to the detection results; A classification module, connected to the detection module, for analyzing the actual rectangular material information, drawing a material information map based on the material information analysis result, classifying the actual rectangular materials according to the material information map analysis result, and obtaining a material classification result; A strategy determination module, connected to the classification module, for sorting and transmitting a plurality of the actual rectangular materials to the first circulation buffer line or the second circulation buffer line respectively based on the classification result, sorting the actual rectangular materials in the first circulation buffer line and the second circulation buffer line respectively, and determining a preset palletizing strategy based on the palletizing tray information and the sorting result; A judgment module, connected to the strategy determination module, for determining a target rectangular material based on a preset stacking strategy, identifying whether the target rectangular material meets a preset grabbing condition through a visual detection device, and if so, placing the target rectangular material in a stacking tray through a grabbing mechanism and adjusting the stacking position accordingly, and if not, the target rectangular material continues to circulate in the circulation buffer line; A calculation module, connected to the judgment module, for calculating a preset stacking position of the target rectangular material based on the target material information corresponding to the target rectangular material and a three-dimensional packing algorithm; an adjustment module, connected to the calculation module, for generating a target rectangular material model based on the target material information, generating a preview palletizing model based on the target rectangular material model and the preset palletizing position, analyzing the preview palletizing model, determining the dumping risk based on the analysis result, adjusting the preset palletizing position based on the dumping risk, and acquiring the adjusted palletizing position; The palletizing determination module is connected to the adjustment module and is used to analyze the actual palletizing layout of the palletizing tray and determine whether the material palletizing is completed based on the analysis result.

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