Flexible package accurate removing system and working method thereof

Abstract

The invention relates to the technical field of flexible package quality detection, and provides an accurate flexible package rejecting system which comprises a visual detection module, a floating length calculation module, a defect tracking module, a rejecting module and a control module. The floating length calculation module comprises an absolute value encoder and a floating roller assembly, the absolute value encoder is arranged on the floating roller assembly to detect the real-time swing angle of the floating roller assembly, the defect tracking module comprises an incremental encoder, and the incremental encoder is connected with the algorithm module and the floating length calculation module. The visual detection module, the floating length calculation module, the defect tracking module and the elimination module are all connected with the control module. The moving distance of the defective object is tracked in real time through an incremental encoder of the defect tracking module, and the accuracy of tracking and removing the defective object in real time is improved by combining the coiled material length, obtained by the floating length calculation module, of the floating roller area. The invention further discloses a working method.

Description

Technical Field

[0001] The invention belongs to the technical field of soft package quality detection, and in particular relates to a soft package precise rejection system and a working method thereof. Background Art

[0002] At present, in the soft packaging industry, in order to improve the appearance quality of products, more and more manufacturers have begun to install online visual inspection equipment for printing quality on bag making machines and other equipment, and accurately track defective products after they are detected. Finally, the defective bags are removed after the rolls are made into complete bags. At present, accurate tracking of detected defects has become the most important pain point. The operation mode of the roll on most equipment such as soft packaging bag making machines is first to unwind at a uniform speed in the unwinding section, and then to change to intermittent feeding through the floating roller area. The change from uniform feeding to intermittent feeding is mainly due to the change of the movement state of the floating roller.

[0003] Those skilled in the art generally believe that the function of the floating roller is tension control, and that the swing range of the floating roller is fixed. As long as the swing range is known, the length of the coil in the floating area can be known, and the position to be removed can be known by calculation. However, the above method still generally results in inaccurate removal, and this problem has existed for a long time. The applicant found that the main reason for the above technical problem is that the unwinding speed before the floating roller and the indirect movement speed of the coil behind the floating roller are often mismatched, so the swing range of each complete swing of the floating roller is actually constantly changing, which in turn causes the length of the coil in the floating area corresponding to each complete swing of the floating roller to change.

[0004] In order to solve the above technical problems, the present invention designs a flexible package precise rejection system and a working method thereof. Summary of the invention

[0005] The invention provides a flexible package precise rejection system and a working method thereof, aiming to solve the problem of continuous change in the length of a coil in a floating roller area.

[0006] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a flexible packaging precise rejection system, comprising a visual inspection module, a floating length calculation module, a defect tracking module, a rejection module and a control module, wherein the visual inspection module comprises a visual image acquisition device and an algorithm module, the floating length calculation module comprises an absolute value encoder and a floating roller assembly, the absolute value encoder is arranged in the floating roller assembly to detect the real-time swing angle of the floating roller, the defect tracking module comprises an incremental encoder, the incremental encoder is connected to the algorithm module and the floating length calculation module, and the visual inspection module, the floating length calculation module, the defect tracking module and the rejection module are all connected to the control module.

[0007] Based on the above technical solution, the floating roller assembly includes a feeding roller, a feeding roller, a floating roller and a rotating member, the rotating member is connected to the floating roller to drive the floating roller to swing, and the absolute encoder is arranged on the rotating member.

[0008] Based on the above technical solution, the flexible package precision rejection system further includes a first travel switch and a second travel switch, which are respectively used to detect whether the floating roller swings to a first preset angle value and a second preset angle value.

[0009] On the basis of the above technical solution, the flexible packaging precise rejection system further comprises an unwinding mechanism, wherein the unwinding mechanism is provided with an unwinding end, the unwinding end is provided with a roller, and the incremental encoder is provided on the roller to measure the unwinding length.

[0010] Based on the above technical solution, the floating roller is an upper floating roller, a lower floating roller, a concave-convex serrated floating roller, or an upper and lower floating roller.

[0011] Based on the above technical solution, the flexible packaging precision rejection system also includes a display module and an alarm module for displaying defect images and alarm prompts.

[0012] In the second aspect, the present application provides a working method of a flexible packaging precision rejection system, which is applied to a flexible packaging precision rejection system as described in any one of the above embodiments, and includes the following steps: obtaining a detection picture of a visual image acquisition device, and judging whether an object in the detection picture has defects through an algorithm module; in the case of defects in the object, obtaining an incremental encoder to record the current running distance Pc of the defective object, the corresponding distance Pp when the object passes through the visual image acquisition device, and the distance De from the visual image acquisition device to the rejection module; obtaining the floating roller swing angle data measured by the absolute encoder, and calculating the coil length Df in the floating roller area; in the case of Pc=Pp+De+Df, the control module sends a rejection signal to the rejection module, and the rejection module rejects the defective object.

[0013] Optionally, obtaining the floating roller swing angle data measured by the absolute encoder, and calculating the coil length Df in the floating roller area includes: obtaining the initial data measured by the absolute encoder; calculating the reference angle of the floating roller by using basic parameters and the initial data; again obtaining the real-time swing angle data of the floating roller measured by the absolute encoder; and calculating the coil length Df in the floating roller area by using the reference angle and real-time swing angle data of the floating roller.

[0014] On the basis of the above technical scheme, the coil length Df in the floating roller area is calculated by using the reference angle and real-time swing angle data of the floating roller, including: calculating the distance between the loading roller and the floating roller and the distance between the lower loading roller and the floating roller by using the reference angle and real-time swing angle of the floating roller; calculating the coil length Df in the floating roller area by using the distance between the loading roller and the floating roller, the distance between the lower loading roller and the floating roller, the distance between the loading roller and the lower loading roller, and the diameters of the loading roller, the lower loading roller and the floating roller.

[0015] Based on the above technical solution, the coil length Df in the floating roller area includes the first section, the second section, the third section, the fourth section and the fifth section. The first section is the winding part of the feeding roller, the second section is the suspended part from the feeding roller to the floating roller, the third section is the winding part of the floating roller, the fourth section is the suspended part from the floating roller to the unloading roller, and the fifth section is the winding part of the unloading roller.

[0016] Compared with the related art, the beneficial effects of the present invention are as follows: 1. The present invention sets a visual inspection module, and the visual image acquisition device collects the inspection picture and transmits it to the control module. The algorithm module determines whether the object has defects, and the absolute value encoder of the floating length calculation module is used to detect the real-time swing angle data of the floating roller to calculate the coil length of the floating roller area. After the visual inspection module detects the defective object, the incremental encoder of the defect tracking module is used to track the movement distance of the defective object in real time, and the coil length of the floating roller area obtained by the floating length calculation module is combined to improve the accuracy of real-time tracking of the defective object. When the defect tracking module detects that the defective object moves to the position of the rejection module, it sends a rejection signal to the control module, and the control module controls the rejection module to reject the defective object.

[0017] 2. The present invention sets a first travel switch and a second travel switch to detect whether the floating roller swings to the first preset angle value or the second preset angle value. When the floating roller swings to the first preset angle value, the first travel switch is triggered, and the first travel switch transmits a signal to the control module, and the control module controls to reduce the unwinding speed. When the floating roller swings to the second preset angle value, the second travel switch is triggered, and the second travel switch transmits a signal to the control module, and the control module controls to increase the unwinding speed. When the unwinding speed in front of the floating roller and the indirect movement speed behind the floating roller are not matched, the unwinding speed in front of the floating roller area is adjusted to prevent the minimum swing angle or the maximum swing angle of the floating roller from exceeding the first preset angle or the second preset angle. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the prior art descriptions are briefly introduced below. Obviously, the drawings described below are only one embodiment of the present invention, and for ordinary technicians in this field, other implementation drawings can be derived from the provided drawings without creative work.

[0019] Figure 1 It is a structural schematic diagram of a soft package precision rejection system provided by the present invention; Figure 2 It is a flow chart of a working method of a soft packaging precise rejection system provided by the present invention; Figure 3 It is a structural schematic diagram of a floating roller assembly of a soft package precision rejection system provided by the present invention; Figure 4 It is a structural schematic diagram of a floating roller assembly of another soft package precision rejection system provided by the present invention. DETAILED DESCRIPTION

[0020] The present invention will be further described below in conjunction with the accompanying drawings and examples: Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be understood as limiting the present invention.

[0021] In the description of the present invention, it should be noted that, 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 directly connected or indirectly connected through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0022] In the description of the present invention, it should be understood that the terms "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside" and "outside" etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0023] Combination Figure 1As shown, an embodiment of the present disclosure provides a flexible packaging precision rejection system, including a visual inspection module, a floating length calculation module, a defect tracking module, a rejection module and a control module, wherein the visual inspection module includes a visual image acquisition device and an algorithm module, the floating length calculation module includes an absolute value encoder and a floating roller assembly, the absolute value encoder is arranged on the floating roller assembly to detect the real-time swing angle of the floating roller assembly, the defect tracking module includes an incremental encoder, the incremental encoder is connected to the algorithm module and the floating length calculation module, and the visual inspection module, the floating length calculation module, the defect tracking module and the rejection module are all connected to the control module.

[0024] The flexible packaging precise rejection system provided by the embodiment of the present disclosure is adopted, by setting a visual inspection module, a visual image acquisition device collects the inspection picture and transmits it to the control module, an algorithm module is used to determine whether the object has defects, and the absolute value encoder of the floating length calculation module is used to detect the real-time swing angle data of the floating roller to calculate the coil length of the floating roller area. After the visual inspection module detects the defective object, the incremental encoder of the defect tracking module is used to track the movement distance of the defective object in real time, and the coil length of the floating roller area obtained by the floating length calculation module is combined to improve the accuracy of real-time tracking of defective objects. When the defect tracking module detects that the defective object moves to the rejection module position, a rejection signal is sent to the control module, and the control module controls the rejection module to reject the defective object.

[0025] Based on the above technical solution, the floating roller assembly includes a feeding roller, a feeding roller, a floating roller and a rotating member, the rotating member is connected to the floating roller to drive the floating roller to swing, and the absolute encoder is arranged on the rotating member.

[0026] Based on the above technical solution, the flexible package precision rejection system further includes a first travel switch and a second travel switch, which are respectively used to detect whether the floating roller swings to a first preset angle value and a second preset angle value.

[0027] Specifically, when the floating roller swings to a first preset angle value, the first travel switch is triggered, and the first travel switch transmits a signal to the control module, and the control module controls to reduce the unwinding speed. When the floating roller swings to a second preset angle value, the second travel switch is triggered, and the second travel switch transmits a signal to the control module, and the control module controls to increase the unwinding speed.

[0028] Compared with the related art, the swing range of the floating roller changes in real time. As the swing range of the floating roller changes, the floating roller will reach a maximum limit angle or a minimum limit angle (i.e., a first preset angle value and a second preset angle value) when it swings. The setting of the first travel switch and the second travel switch can enable the floating roller to transmit a signal to the control module when it reaches the first preset angle value or the second preset angle value during movement. The control module controls the unwinding speed in front of the floating roller area to prevent the minimum swing angle and the maximum swing angle of the floating roller from exceeding the first preset angle and the second preset angle.

[0029] On the basis of the above technical solution, the flexible packaging precise rejection system further comprises an unwinding mechanism, wherein the unwinding mechanism is provided with an unwinding end, the unwinding end is provided with a roller, and the incremental encoder is provided on the roller to measure the unwinding length.

[0030] Based on the above technical solution, the floating roller is an upper floating roller, a lower floating roller, a concave-convex serrated floating roller, or an upper and lower floating roller.

[0031] Based on the above technical solution, the flexible packaging precision rejection system also includes a display module and an alarm module for displaying defect images and alarm prompts.

[0032] Specifically, the visual image acquisition device is a line scan color camera.

[0033] Combination Figure 2 As shown, the embodiment of the present disclosure provides a working method of a flexible package precision rejection system, which is applied to the flexible package precision rejection system as described in any one of the above embodiments, and includes the following steps: S201, obtaining a detection picture of a visual image acquisition device, and determining whether an object in the detection picture has defects through an algorithm module; S202, when there is a defect in the object, obtain the incremental encoder to record the current running distance Pc of the defective object, the corresponding distance Pp when the object passes through the visual image acquisition device, and the distance De from the visual image acquisition device to the rejection module; S203, obtaining the swing angle data of the floating roller measured by the absolute encoder, and calculating the coil length Df in the floating roller area; S204, when Pc=Pp+De+Df, the control module sends a rejection signal to the rejection module, and the rejection module rejects the defective objects.

[0034] Specifically, if an object has defects, in the absence of a floating roller, when Pc=Pp+De, a rejection signal can be issued. When there is a floating roller in the object's forward path, the object needs to advance by the length of the coil in the floating roller area to reach the predetermined rejection position. The length of the coil when the floating roller swings to the shortest length is recorded as Df. Then, when Pc=Pp+De+Df, a rejection signal can be issued. When the floating roller runs to the shortest coil length, it means that a bag on the flexible packaging bag making machine has run to the cutter or ironing knife position and stopped. Then, as the unwinding end continues to unwind, the coil in the floating roller area begins to extend, while the bag at the cutter or ironing knife position remains stationary. When the cutter or ironing knife completes an action, the bag making machine quickly pulls the material, and the length of the coil in the floating roller area gradually shrinks to the shortest position, completing a cycle of action. As long as the rejection signal is issued within one cycle, the rejection command can be matched with the cut bag.

[0035] Optionally, obtaining the floating roller swing angle data measured by the absolute encoder, and calculating the coil length Df in the floating roller area includes: obtaining the initial data measured by the absolute encoder; calculating the reference angle of the floating roller by using basic parameters and the initial data; again obtaining the real-time swing angle data of the floating roller measured by the absolute encoder; and calculating the coil length Df in the floating roller area by using the reference angle and real-time swing angle data of the floating roller.

[0036] Specifically, the basic parameters include the distance L between the rotating member and the feeding roller. AB , the distance between the rotating part and the unloading roller L AC , the distance between the rotating part and the floating roller L AD , the distance between the upper and lower rollers L BC , the distance L between the loading roller and the floating roller in the initial state BD , and the diameters d of the feed roller, the feed roller and the floating roller. ∠BAC=arccos[(L AB 2 +L AC 2 -L BC 2 ) / 2*L AB *L AC ], ∠BAD=arccos[(L AB 2 +L AD 2 -L BD 2 ) / 2*L AB *L AD ], calculate the reference angle Angle = encoder initial data / 4096*360°+∠BAD through the basic parameters and the initial data measured by the absolute encoder.

[0037] On the basis of the above technical scheme, the coil length Df in the floating roller area is calculated by using the reference angle and real-time swing angle data of the floating roller, including: calculating the distance between the loading roller and the floating roller and the distance between the lower loading roller and the floating roller by using the reference angle and real-time swing angle of the floating roller; calculating the coil length Df in the floating roller area by using the distance between the loading roller and the floating roller, the distance between the lower loading roller and the floating roller, the distance between the loading roller and the lower loading roller, and the diameters of the loading roller, the lower loading roller and the floating roller.

[0038] Combination Figure 3 As shown, the reference angle Angle of the floating roller calculated by the above embodiment and the real-time data of the encoder are used to calculate ∠BAD=Angle-(real-time data of the encoder / 4096*360°), ∠CAD=Angle-(real-time data of the encoder / 4096*360°)-∠BAC, and the distance L between the feeding roller and the floating roller is obtained according to ∠BAD and ∠CAD. BD 2 =L AB 2 +L AD 2 -2*L AB *L AD *cos∠BAD, distance L between unloading roller and floating roller CD 2 =L AC 2 +L AD 2 -2*L AC *L AD cos∠CAD.

[0039] Based on the above technical solution, the coil length Df in the floating roller area includes the first section, the second section, the third section, the fourth section and the fifth section. The first section is the winding part of the feeding roller, the second section is the suspended part from the feeding roller to the floating roller, the third section is the winding part of the floating roller, the fourth section is the suspended part from the floating roller to the unloading roller, and the fifth section is the winding part of the unloading roller.

[0040] like Figure 4 As shown, the distance L between the feeding roller and the floating roller is calculated from the above embodiment. BD And the distance L between the unloading roller and the floating roller CD , and the distance L between the upper and lower rollers is known BC And the diameter d of the loading roller, the lower roller and the floating roller.

[0041] First, calculate ∠BCD, ∠CBD and ∠CDB according to the cosine theorem. Taking ∠BCD as an example, ∠BCD=arccos[(L BC 2+L CD 2 -L BD 2 ) / 2*L BC *L CD ], the calculation of ∠CBD and ∠CDB is the same as ∠BCD, and ∠DCH=arccos(d / L CD ), and obtain the suspended part L from the second feeding roller to the floating roller HJ =L CD *sin(∠DCH).

[0042] Knowing that ∠BCG=45°, ∠GCH=45°-(∠DCH-∠BCD), we can get the winding part L of the first section of the feeding roller. GH =π*d*(∠GCH / 360).

[0043] From ∠DBL=arccos(d / BD), ∠JDK=360°-∠CDJ-∠BDK-∠BDC=360°-∠DCH-∠DBL-∠BDC, we can get the winding part L of the third floating roller: JK =π*d*(∠JDK / 360), the suspended part from the fourth floating roller to the unloading roller L KL =L BD *sin(∠DBL).

[0044] Knowing that ∠CBM=45°, ∠LBM=45°-(∠DBL-∠CBD), we can get the winding part L of the fifth section of the unloading roller. LM =π*d*(∠LBM / 360).

[0045] Get the coil length Df=L in the floating roller area GH +L HJ +L JK +L KL +L LM .

[0046] Optionally, when two floating rollers are arranged in the floating roller area, the area may be divided into two and the calculation in the above embodiment may be performed to obtain the coil length in the floating roller area.

[0047] The present invention is described above by way of examples, but the present invention is not limited to the above specific embodiments, and any changes or modifications made based on the present invention belong to the scope of protection claimed by the present invention.

Claims

1. A flexible packaging precision rejection system, characterized in that: It includes a visual inspection module, a floating length calculation module, a defect tracking module, a rejection module and a control module. The visual inspection module includes a visual image acquisition device and an algorithm module. The floating length calculation module includes an absolute value encoder and a floating roller assembly. The absolute value encoder is arranged on the floating roller assembly to detect the real-time swing angle of the floating roller assembly. The defect tracking module includes an incremental encoder. The incremental encoder is connected to the algorithm module and the floating length calculation module. The visual inspection module, the floating length calculation module, the defect tracking module and the rejection module are all connected to the control module.

2. The flexible packaging precise rejection system according to claim 1, characterized in that: The floating roller assembly comprises a feeding roller, a feeding roller, a floating roller and a rotating member. The rotating member is connected to the floating roller to drive the floating roller to swing. The absolute value encoder is arranged on the rotating member.

3. The flexible packaging precise rejection system according to claim 2, characterized in that: It also includes a first travel switch and a second travel switch, which are respectively used to detect whether the floating roller swings to the first preset angle value and the second preset angle value.

4. The flexible packaging precise rejection system according to claim 2, characterized in that: The floating roller is an upper floating roller, a lower floating roller, a concave-convex serrated floating roller, or an upper and lower floating roller.

5. The flexible packaging precise rejection system according to any one of claims 1 to 4, characterized in that: It also includes an unwinding mechanism, wherein the unwinding mechanism is provided with an unwinding end, the unwinding end is provided with a roller, and the incremental encoder is provided on the roller to measure the unwinding length.

6. The flexible packaging precise rejection system according to any one of claims 1 to 4, characterized in that: It also includes a display module and an alarm module, which are used to display defect images and alarm prompts.

7. A working method of a flexible package precision rejection system, applied to the flexible package precision rejection system as claimed in any one of claims 1 to 6, characterized in that: The following steps are involved: Obtain the detection picture of the visual image acquisition device, and determine whether there are defects in the object in the detection picture through the algorithm module; In the case of defects in the object, obtain the current running distance Pc of the defective object recorded by the incremental encoder, the corresponding distance Pp when the object passes through the visual image acquisition device, and the distance De from the visual image acquisition device to the rejection module; Obtain the swing angle data of the floating roller measured by the absolute encoder and calculate the coil length Df in the floating roller area; When Pc=Pp+De+Df, the control module sends a rejection signal to the rejection module, and the rejection module rejects the defective objects.

8. The working method of the flexible packaging precise rejection system according to claim 7, characterized in that: Obtaining the swing angle data of the floating roller measured by the absolute encoder and calculating the web length Df in the floating roller area includes: Get the initial data of the absolute encoder measurement; Calculate the reference angle of the floating roller through basic parameters and initial data; The real-time swing angle data of the floating roller measured by the absolute encoder is obtained again; The web length Df in the dancing roller area is calculated by the reference angle of the dancing roller and the real-time swing angle data.

9. The working method of the flexible packaging precise rejection system according to claim 8, characterized in that: The web length Df in the floating roller area is calculated by using the reference angle and real-time swing angle data of the floating roller, including: The distance between the loading roller and the floating roller and the distance between the unloading roller and the floating roller are calculated by the reference angle and the real-time swing angle of the floating roller; The web length Df in the floating roller area is calculated by the distance between the upper and lower rollers, the distance between the lower and upper rollers, the distance between the upper and lower rollers, and the diameters of the upper, lower and upper rollers.

10. The working method of the flexible packaging precise rejection system according to claim 9, characterized in that: The coil length Df in the floating roller area includes the first section, the second section, the third section, the fourth section and the fifth section. The first section is the winding part of the feeding roller, the second section is the suspended part from the feeding roller to the floating roller, the third section is the winding part of the floating roller, the fourth section is the suspended part from the floating roller to the lower material roller, and the fifth section is the winding part of the lower material roller.

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