Electrical system and control method for high speed stopper device of high speed roller conveyor line

Abstract

The present application relates to the technical field of automatic logistics roller conveying line in factory, and provides an electrical system and control method for high-speed stopper equipment of high-speed roller conveying line, which comprises a controller, an ASI gateway, an ASI electric roller driving module, a proximity switch, a direct-current brushless motor driver and other components, and precise control of the stopper is realized through a preset control strategy knowledge base. The present application uses a direct-current brushless motor as a power source, solving the problem of slow and unstable beats of the traditional cylinder driving mode on the high-speed conveying line. Through fine control strategy and real-time monitoring feedback mechanism, accurate and efficient action of the stopper on the high-speed conveying line is realized, and the overall operation efficiency and stability of the conveying line are improved.

Description

Technical Field

[0001] This invention relates to the field of automated roller conveyor technology in factory logistics, and more particularly to the electrical system and control method for high-speed stop devices in high-speed roller conveyors. Background Technology

[0002] Stoppers are devices used to assist in controlling the stopping position of containers transported on conveyor lines. When containers are transported at high speeds on conveyor lines, they have significant inertia. If they were to stop normally, the stopping position would vary depending on the weight of the goods inside. Some containers need to stop precisely at designated locations on the conveyor line, such as where there are transfer machines. Therefore, stoppers are necessary. When containers transported at high speeds need to stop accurately on the designated storage area, stoppers are used to assist in stopping them.

[0003] The stop devices currently used in the project are powered by cylinders. However, factories with high safety standards, for safety reasons, do not install air sources within the factory premises and prohibit the use of air pumps. Therefore, the stop devices cannot be used without a power source. Even when an air source is available, the stop device's lifting speed and operating cycle depend on the stability of the air pressure. The control method for the stop devices is unsuitable for high-speed conveyor lines, making accurate control of the stop device's action during high-speed transport difficult.

[0004] Most existing warehousing conveyor equipment manufacturers have few high-speed conveyor projects, and stoppers are typically used on non-high-speed conveyors. Control methods suitable for non-high-speed conveying, using cylinders as a power source, are low-cost and easy to maintain. However, high-speed conveying requires fast-paced operation of the stoppers. Using cylinder-powered stoppers in this situation results in a rapid stopper cycle, compromises stability, and makes the control methods unsuitable for high-speed conveyor applications. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention proposes a control method and control system for goods-to-person picking station equipment, solving the problems of slow cycle time and instability when the stopper is applied to a high-speed conveyor line. The technical solution of this invention replaces the power source with a faster and more stable power source, and designs an electrical scheme for this purpose, which can control the stopper and is convenient for wiring and debugging.

[0006] To solve the above-mentioned technical problems, the specific technical solution of the present invention is as follows:

[0007] In a first aspect, the present invention provides an electrical system for a high-speed stop device in a high-speed roller conveyor line, comprising:

[0008] The electrical system for high-speed stop devices in high-speed roller conveyor lines is characterized by comprising: a controller, an ASI gateway, an ASI electric roller drive module, an upper limit proximity switch, a lower limit proximity switch, a DC brushless motor drive, a DC brushless motor driver, and a stop DC brushless motor.

[0009] The controller establishes a communication connection with the ASI gateway. The ASI gateway connects to the distributed ASI electric roller drive module via the ASI bus. The ASI electric roller drive module connects to the upper limit proximity switch and the lower limit proximity switch, and receives the DC brushless motor driver fault signal. The DC brushless motor driver fault signal is sent to the ASI electric roller drive module through the roller fault input signal of the ASI electric roller drive module. The ASI electric roller drive module outputs start signal and direction signal to control the DC brushless motor driver, which is used to make the DC brushless motor rotate forward and reverse, thereby driving the stop baffle to move up and down.

[0010] The controller includes:

[0011] The data acquisition unit acquires information about the stopper device and its installation location.

[0012] The control measurement matching unit matches the stopper installation position information with the preset control strategy knowledge base to obtain the control strategy corresponding to the stopper installation position. The control strategy knowledge base includes the stopper paired with the straight section control strategy, the stopper paired with the transfer machine exit section control strategy, the stopper paired with the transfer machine inlet section control strategy, and the stopper paired with the swing wheel machine exit section control strategy.

[0013] The control command is converted to initialize the stopper. When the stopper descends to the lower limit, the control strategy corresponding to the installation position of the stopper is converted into control information.

[0014] The control command execution unit sends control information to the DC brushless motor driver of the stop. The control information includes a start signal and a direction signal. The start signal and the direction signal control the DC brushless motor driver of the stop to make the DC brushless motor rotate forward and backward, thereby driving the stop baffle to move up and down.

[0015] Furthermore, the electrical system for a high-speed stop device in a high-speed roller conveyor line according to the present invention includes a stop device coupled with a linear segment control strategy, comprising:

[0016] After the stop control starts, initialization is performed first. The stop descends to the lower limit and the wave of the straight segment controlled by the host computer is checked. If it is wave collection control, it is checked whether the current station is releasing boxes. If not, the stop rises to the upper limit. If the current station is releasing boxes, the stop rises to the upper limit after the turnover box leaves the current station's accumulation and reaches the next station's accumulation. Then, after the current station finishes entering the box and encounters the stop's calibration position, the stop is detected to be in the raised state, and the current station stops the box release. Wave collection is completed. If it is wave release, the host computer controls the stop to release the wave. After the stop descends to the lower limit, the current station's accumulation detects that the stop has descended completely, and the current station's turnover box is released. Wave release control is completed, and the stop control combined with the straight segment control ends.

[0017] Furthermore, the electrical system for the high-speed stop device of the high-speed roller conveyor line described in this invention, wherein the stop device is combined with the control strategy for the box-out section of the transfer machine, includes:

[0018] After the control of the box-out stopper in the transfer section starts, initialization is performed first. The stopper descends to the lower limit position, the previous station's turnover box is discharged, and the current station's transfer section accumulates and sends in a straight box. The host computer command is retrieved to determine whether the turnover box has been transported to the straight section for accumulation. If not, it is determined whether the next station's accumulation section allows the box to enter. If the box is allowed to enter, the current station's turnover box is discharged to the next station. If the turnover box needs to be transported to the straight section for accumulation, the stopper rises to the upper limit position. After the current station's turnover box reaches the stopper calibration position, it is determined whether the accumulation section for accumulation allows the box to enter. If the box is allowed to enter, the current station's transfer box is discharged to the straight section for accumulation, and then the stopper descends to the lower limit position. The control of the box discharge by the stopper and the transfer section ends.

[0019] Furthermore, the electrical system for the high-speed stopper equipment in a high-speed roller conveyor line described in this invention, wherein the stopper is combined with a control strategy for the transfer machine's box-entry section, includes:

[0020] After the stopper is used in conjunction with the transfer machine's box entry section control, it is initialized first. The left stopper descends to the lower limit, and the right stopper descends to the lower limit.

[0021] Determine the direction of the transfer machine entering the container. If it is moving straight into the container, after the container is in place at this station, determine whether the next station's storage section allows the container to enter. If the container is allowed to enter, the container is moved from this station to the next station's storage section.

[0022] If the left-hand box is being transferred, the left stop will descend to the lower limit and the right stop will rise to the upper limit. Then, it will be determined whether the left stop has descended to the lower limit. After the left stop has descended to the lower limit, the turnover box will be transported from the left-hand box transfer straight section to the current station's storage. After encountering the right stop baffle, the position will be calibrated. After the current station's turnover box has entered the storage position, both the left and right stops will descend to the lower limit. After both have descended to the lower limit, it will be determined whether the next station's storage section allows the box to enter. If the box is allowed to enter, the current station's turnover box will exit to the next station's storage.

[0023] If the transfer box is entering from the right, the right stop will descend to the lower limit and the left stop will rise to the upper limit. Then, it will be determined whether the right stop has descended to the lower limit. After the right stop has descended to the lower limit, the turnover box will be transported from the transfer box entering from the right to the straight section to the current station for storage. After the turnover box touches the left stop baffle, its position will be adjusted. After the turnover box enters the current station, both the left and right stops will descend to the lower limit. After both have descended to the lower limit, it will be determined whether the next station for storage is allowed to enter the box. If the turnover box is allowed to enter, the turnover box will exit the current station for storage at the next station. The control of the stop and the transfer machine section for the turnover box entering the box ends.

[0024] Furthermore, the electrical system for the high-speed stopper equipment of the high-speed roller conveyor line described in this invention, wherein the stopper is combined with the control strategy for the outlet section of the swing wheel machine, includes:

[0025] After the stopper and the balance wheel machine box-out control start, initialization is performed first. The balance wheel machine turns to the straight-line direction, the stopper descends to the lower limit, the previous station's turnover box is discharged, and the current station's transfer section accumulates and moves straight into the box. The host computer command is retrieved to determine whether the turnover box has been transported to the balance wheel machine's box-out straight section for accumulation. If not, it is determined whether the next station's accumulation section allows box entry. If box entry is allowed, the balance wheel machine turns to the straight-line box-out direction, and the current station's turnover box is discharged to the next station. If the turnover box needs to be transported to the balance wheel machine's box-out straight section for accumulation, the stopper rises to the upper limit. After the current station's turnover box reaches the stopper calibration position, the balance wheel machine turns to the balance wheel branch box-out direction. It is determined whether the balance wheel branch box-out section's accumulation section allows box entry. If box entry is allowed, the current station's balance wheel machine discharges the box to the balance wheel machine's branch box-out straight section, and then the stopper descends to the lower limit. The stopper and balance wheel machine box-out control ends.

[0026] Secondly, the present invention provides a control method for a high-speed stop device in a high-speed roller conveyor line, applied to the electrical system of the high-speed stop device in the high-speed roller conveyor line, comprising:

[0027] Step S101: Obtain the stop device information and the stop device installation location information;

[0028] Step S102: Match the stopper installation position information in the preset control strategy knowledge base to obtain the control strategy corresponding to the stopper installation position. The control strategy knowledge base includes the stopper with straight section control strategy, the stopper with transfer machine box exit section control strategy, the stopper with transfer machine box entry section control strategy, and the stopper with swing wheel machine box exit section control strategy.

[0029] Step S103: Initialize the stopper. When the stopper descends to the lower limit, convert the control strategy corresponding to the installation position of the stopper into control information.

[0030] Step S104: Send control information to the DC brushless motor driver of the stop. The control information includes a start signal and a direction signal. The start signal and the direction signal control the DC brushless motor driver of the stop to make the DC brushless motor rotate forward and backward, thereby driving the stop baffle to move up and down.

[0031] Furthermore, in the control method for high-speed stopper equipment in a high-speed roller conveyor line according to the present invention, step S102 includes:

[0032] The stopper combined with the linear segment control strategy includes initialization after the stopper control starts. The stopper descends to the lower limit and the host computer controls the linear segment wave. If it is wave collection control, it checks whether the current station is releasing boxes. If not, the stopper rises to the upper limit. If the current station is releasing boxes, the stopper rises to the upper limit after the box leaves the current station and reaches the next station. Then, after the current station finishes receiving boxes and encounters the stopper calibration position, it detects the stopper's raised state and stops the current station's box release, completing the wave collection. If it is a wave release, the host computer controls the stopper to release the wave. After the stopper descends to the lower limit, the current station detects the stopper's descent is complete, and the current station releases the box, completing the wave release control. The stopper combined with the linear segment control ends.

[0033] Furthermore, in the control method for high-speed stopper equipment in a high-speed roller conveyor line according to the present invention, step S102 includes:

[0034] The control strategy for the stopper combined with the transfer machine's box-out section includes the following steps: After the stopper control for the box-out section begins, initialization is performed. The stopper descends to the lower limit, the previous station's turnover box is discharged, and the current station's transfer section accumulates and moves straight into the box. The host computer's instructions are retrieved to determine whether the turnover box has been transported to the straight section for accumulation. If not, it is determined whether the next station's accumulation section allows box entry. If box entry is allowed, the current station's turnover box is discharged to the next station. If the turnover box needs to be transported to the straight section for accumulation, the stopper rises to the upper limit. After the current station's turnover box reaches the stopper's calibration position, it is determined whether the transfer section's accumulation section allows box entry. If box entry is allowed, the current station's transfer box is discharged to the straight section for accumulation, and then the stopper descends to the lower limit. The stopper combined with the transfer machine's box-out section control ends.

[0035] Furthermore, in the control method for high-speed stopper equipment in a high-speed roller conveyor line according to the present invention, step S102 includes:

[0036] The control strategy for the stopper combined with the transfer machine entering the box section includes initialization after the stopper combined with the transfer machine entering the box section control starts, the left stopper descends to the lower limit, and the right stopper descends to the lower limit.

[0037] Determine the direction of the transfer machine entering the container. If it is moving straight into the container, after the container is in place at this station, determine whether the next station's storage section allows the container to enter. If it is allowed, the container will be moved from this station to the next station's storage section.

[0038] If the left-hand box is being transferred, the left stop will descend to the lower limit and the right stop will rise to the upper limit. Then, it will be determined whether the left stop has descended to the lower limit. After the left stop has descended to the lower limit, the turnover box will be transported from the left-hand box transfer straight section to the current station's storage. After encountering the right stop baffle, the position will be calibrated. After the current station's turnover box has entered the storage position, both the left and right stops will descend to the lower limit. After both have descended to the lower limit, it will be determined whether the next station's storage section allows the box to enter. If the box is allowed to enter, the current station's turnover box will exit to the next station's storage.

[0039] If the transfer box is entering from the right, the right stop will descend to the lower limit and the left stop will rise to the upper limit. Then, it will be determined whether the right stop has descended to the lower limit. After the right stop has descended to the lower limit, the turnover box will be transported from the transfer box entering from the right to the straight section to the current station for storage. After the turnover box touches the left stop baffle, its position will be adjusted. After the turnover box enters the current station, both the left and right stops will descend to the lower limit. After both have descended to the lower limit, it will be determined whether the next station for storage is allowed to enter the box. If the turnover box is allowed to enter, the turnover box will exit the current station for storage at the next station. The control of the stop and the transfer machine section for the turnover box entering the box ends.

[0040] Furthermore, in the control method for high-speed stopper equipment in a high-speed roller conveyor line according to the present invention, step S102 includes:

[0041] The control strategy for the box-out section of the stopper combined with the balance wheel machine includes the following steps: After the control starts, initialization is performed, the balance wheel machine turns to the straight-line direction, the stopper descends to the lower limit, the previous station's turnover box is discharged, and the current station's transfer section accumulates and moves straight-line into the box. The system retrieves instructions from the host computer to determine if the turnover box has been transported to the straight-line section of the balance wheel machine for accumulation. If not, it determines whether the next station's accumulation section allows box entry. If box entry is allowed, the balance wheel machine turns to the straight-line direction for box discharge. Afterwards, the turnover box from this station is sent to the next station. If the turnover box needs to be transported to the straight section of the balance wheel machine for accumulation, the stop will rise to the upper limit. After the turnover box from this station is in place and hits the stop calibration position, the balance wheel machine will turn to the direction of the balance wheel branch exit. It will then determine whether the accumulation of the balance wheel branch exit section is allowed to enter the box. If it is allowed, the balance wheel machine from this station will exit the box to the straight section of the balance wheel machine branch exit. Then the stop will descend to the lower limit. The stop and the balance wheel machine section exit control will then end.

[0042] The beneficial effects of this invention are as follows:

[0043] This invention uses a DC brushless motor as the power source for the stop, which has a faster response speed and higher stability compared to the traditional cylinder drive method. This enables the stop to perform its actions accurately and quickly on high-speed conveyor lines, thereby improving the overall operating efficiency of the conveyor line.

[0044] This invention utilizes a pre-set control strategy knowledge base, which includes optimized control strategies for different conveyor line scenarios. These strategies can be flexibly matched and executed based on the installation location and specific requirements of the stoppers, thereby enhancing the system's flexibility and adaptability. This enables the system to cope with conveyor lines with different layouts and operational needs, improving equipment utilization.

[0045] This invention uses upper and lower limit proximity switches to monitor the position of the stop in real time, ensuring that the stop remains in the correct position during operation. Simultaneously, the DC brushless motor driver can promptly feed back fault signals to the control system, enabling timely fault detection and handling, thus improving system reliability and stability.

[0046] This invention achieves precise control of the stop device through a sophisticated control strategy and an efficient electrical system, which can reduce production delays or downtime caused by inaccurate or unstable stop device operation, thereby improving the overall operating efficiency of the conveyor line.

[0047] The brushless DC motor used in this invention has a long service life and low maintenance costs. At the same time, the improved system stability and accuracy reduce downtime for repairs due to malfunctions, further lowering operating costs.

[0048] The implementation of this invention significantly improves the automation level of high-speed roller conveyor lines. Through precise electrical systems and control methods, intelligent control of the stop devices is achieved, reducing the need for manual intervention and improving the automation and intelligence level of the production line.

[0049] In summary, this invention effectively solves the problems of slow and unstable cycle time when stoppers are applied to high-speed conveyor lines by changing the power source, designing a dedicated electrical system and control method, pre-setting a control strategy knowledge base, and implementing real-time monitoring and feedback. This improves the overall operating efficiency and stability of the conveyor line, reduces maintenance and operating costs, and enhances the level of automation. Attached Figure Description

[0050] To more clearly illustrate the technical solution of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, those skilled in the art can obtain other drawings based on these drawings without creative effort.

[0051] Figure 1A connection block diagram of the electrical scheme for the high-speed stop provided in an embodiment of the present invention.

[0052] Figure 2 This is a schematic diagram of the installation position of the stopper with a straight section provided in an embodiment of the present invention.

[0053] Figure 3 This is a schematic diagram of the installation position of the stopper with a straight section provided in an embodiment of the present invention.

[0054] Figure 4 This is a schematic diagram showing the installation position of the stopper in conjunction with the transfer machine's box-out section, as provided in an embodiment of the present invention.

[0055] Figure 5 A flowchart illustrating the control method for the stopper combined with the transfer machine's box-out section, as provided in an embodiment of the present invention.

[0056] Figure 6 This is a schematic diagram showing the installation position of the stopper in the loading section of the transfer machine, as provided in an embodiment of the present invention.

[0057] Figure 7 A flowchart illustrating the control method for the stopper combined with the transfer machine's box entry section provided in this embodiment of the invention.

[0058] Figure 8 This is a schematic diagram of the installation position of the stopper paired with the balance wheel machine at the outlet section of the box, as provided in an embodiment of the present invention.

[0059] Figure 9 A flowchart illustrating the control method for the exit section of the stopper combined with the balance wheel mechanism provided in this embodiment of the invention. Detailed Implementation

[0060] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below in conjunction with specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention. The technical solutions provided by various embodiments of this invention will be described in detail below with reference to the accompanying drawings.

[0061] To better understand the purpose of this invention, the invention will now be described in further detail.

[0062] In a first aspect, the present invention provides an electrical system for a high-speed stop device in a high-speed roller conveyor line, comprising:

[0063] The electrical system for high-speed stop devices in high-speed roller conveyor lines is characterized by comprising: a controller, an ASI gateway, an ASI electric roller drive module, an upper limit proximity switch, a lower limit proximity switch, a DC brushless motor drive, a DC brushless motor driver, and a stop DC brushless motor.

[0064] like Figure 1 As shown, the controller establishes a communication connection with the ASI gateway. The ASI gateway connects to the distributed ASI electric roller drive module via the ASI bus. The ASI electric roller drive module connects to the upper limit proximity switch and the lower limit proximity switch, and receives the DC brushless motor driver fault signal. The DC brushless motor driver fault signal is sent to the ASI electric roller drive module through the roller fault input signal of the ASI electric roller drive module. The ASI electric roller drive module outputs a start signal and a direction signal to control the DC brushless motor driver, which is used to make the DC brushless motor rotate forward and reverse, thereby driving the stop baffle to move up and down.

[0065] A communication connection was established between the invention controller and the ASI gateway to create an information transmission channel, enabling the control of the stoppers on the high-speed roller conveyor line. The following is a detailed analysis of this connection and its subsequent functions:

[0066] The controller, as the "brain" of the entire electrical system, is responsible for receiving instructions, processing data, and issuing control signals.

[0067] The ASI gateway acts as a communication interface, converting controller signals into ASI bus protocol signals, enabling stable signal transmission in complex industrial environments. The communication connection allows the controller to acquire real-time status information of the stop and issue control commands as needed.

[0068] Connection between ASI bus and distributed ASI electric roller drive modules: ASI bus is a communication protocol specifically designed for industrial automation, characterized by high speed and reliability. Distributed ASI electric roller drive modules are arranged along the conveyor line, with each module responsible for controlling the electric rollers within a specific area. Through the ASI bus, the controller can communicate with multiple electric roller drive modules simultaneously, achieving centralized control of the entire conveyor line.

[0069] Connection between the ASI electric roller drive module and the proximity switches and brushless DC motor driver: The upper and lower limit proximity switches are used to detect the position of the stop, ensuring that the stop does not exceed the preset range during movement. The brushless DC motor driver controls the forward and reverse rotation of the brushless DC motor, thereby driving the stop plate to move up and down. The ASI electric roller drive module receives position signals from the proximity switches and fault signals from the brushless DC motor driver, and outputs start and direction signals to the brushless DC motor driver based on these signals.

[0070] If the DC brushless motor driver fails, it will immediately send a fault signal to the ASI electric roller drive module.

[0071] Upon receiving a fault signal, the ASI electric roller drive module can relay the fault information to the controller via the ASI bus. The controller then takes appropriate measures based on the fault information, such as stopping the current operation or issuing an alarm, to ensure the safe and stable operation of the system.

[0072] In summary, the communication connection established between the controller and the ASI gateway, along with its subsequent functional design, provides a reliable technical guarantee for the precise control of the stop devices on high-speed roller conveyors. Through this design, the system can acquire the status information of the stop devices in real time and issue precise control commands as needed, while also enabling timely detection and handling of faults.

[0073] The controller includes:

[0074] The data acquisition unit acquires information about the stopper device and its installation location.

[0075] In this invention, the data acquisition unit is responsible for acquiring information about the stop device and the stop device installation location. The stop device information and the stop device installation location information are the basis for the subsequent control strategy formulation and execution.

[0076] The specific functions of the data acquisition unit include, but are not limited to, the basic parameters of the stop, such as its model, size, weight, maximum load-bearing capacity, and operating speed. These parameters are crucial for understanding the performance limits of the stop and ensuring its safe operation.

[0077] Obtain the stop installation location information: The installation location information describes in detail the specific location of the stop on the conveyor line, including the positional relationship of the stop relative to other conveyor line components (such as electric rollers, transfer machines, and swing machines), as well as the information of the specific accumulation section or workstation served by the stop.

[0078] Accurate installation location information is crucial for developing appropriate control strategies. For example, different control strategies are required to ensure smooth operation of the conveyor line depending on the location of the stopper in the straight section, the transfer machine exit section, the transfer machine in the box section, or the swing wheel machine exit section.

[0079] Provides a basis for the formulation of control strategies: By obtaining the equipment information and installation location information of the stop, the controller can identify the specific environment and working requirements of the stop, thereby selecting or formulating the most suitable control strategy.

[0080] Enhancing system flexibility and adaptability: The installation location and control requirements of stoppers will vary depending on different conveyor line layouts and operating scenarios. The data acquisition unit can capture this information in real time, enabling the system to flexibly adjust control strategies to adapt to different operational needs.

[0081] Enhancing system stability: Accurate equipment and location information is a prerequisite for the proper functioning of the stoppers. By continuously monitoring and updating this information, the system can promptly identify and correct potential problems, thereby ensuring the stable operation of the conveyor line.

[0082] In summary, the data acquisition unit plays an indispensable role in this invention. By acquiring information about the stop device and its installation location, the data acquisition unit provides a solid foundation for the formulation and execution of control strategies.

[0083] The control measurement matching unit matches the stopper installation position information with the preset control strategy knowledge base to obtain the control strategy corresponding to the stopper installation position. The control strategy knowledge base includes the stopper paired with the straight section control strategy, the stopper paired with the transfer machine exit section control strategy, the stopper paired with the transfer machine inlet section control strategy, and the stopper paired with the swing wheel machine exit section control strategy.

[0084] The main function of the control measurement matching unit is to match the acquired stop installation position information with a preset control strategy knowledge base, thereby determining the control strategy corresponding to the stop installation position.

[0085] The workflow of the control measurement matching unit is as follows: The control measurement matching unit first receives the stop installation position information provided by the data acquisition unit. The information describes in detail the specific position of the stop on the conveyor line and its operating environment.

[0086] Knowledge base matching: The control measurement matching unit matches this location information with a preset control strategy knowledge base. The knowledge base contains a variety of control strategies for different scenarios and needs, such as a stopper combined with a straight section control strategy, a stopper combined with a transfer machine exit section control strategy, a stopper combined with a transfer machine entry section control strategy, and a stopper combined with a swing wheel machine exit section control strategy, etc.

[0087] The control strategy is meticulously designed based on the different layouts of the conveyor line, the work processes, and the functional requirements of the stoppers, aiming to enable the stoppers to perform their tasks accurately and efficiently in various scenarios. After matching, the control measurement matching unit will output the control strategy corresponding to the installation position of the stopper. The strategy will serve as the basis for the subsequent conversion and execution of control commands, enabling the stopper to operate in a predetermined manner and rhythm.

[0088] Stopper combined with straight section control strategy: For cases where the stopper is installed in the straight section accumulation area, a series of control strategies are designed to ensure that the turnover box stops accurately and is transported smoothly on the straight section.

[0089] Control strategy for stopper and transfer machine in the box delivery section: For scenarios where the stopper and transfer machine are used together to transport turnover boxes in the box delivery section, a corresponding control strategy has been developed to coordinate the actions of the transfer machine and the stopper and improve the box delivery efficiency.

[0090] Control strategy for the loading section of the transfer machine with the stopper: Similar to the unloading section, the control strategy for the loading section also aims to optimize the coordination between the transfer machine and the stopper, so that the turnover box can enter the designated position accurately and quickly.

[0091] Stopper combined with control strategy for the exit section of the swing wheel machine: A special control strategy was designed to meet the special requirements of the exit section of the swing wheel machine, so as to deal with complex actions such as the swing wheel machine turning and branching exit, and to ensure the overall smoothness of the conveyor line.

[0092] By coordinating the control measurement matching unit with the preset control strategy knowledge base, this invention can achieve precise control of the high-speed stopper of the high-speed roller conveyor, meet the operational needs of different scenarios, and improve the overall operating efficiency and stability of the conveyor line.

[0093] The control command is converted to initialize the stopper. When the stopper descends to the lower limit, the control strategy corresponding to the installation position of the stopper is converted into control information.

[0094] The control command conversion module acts as a bridge in the electrical system of the high-speed stop device in a high-speed roller conveyor line. It is responsible for converting the control strategy output by the control measurement matching unit into specific control information so that the execution unit can accurately control the action of the stop. The following is the specific workflow and importance of the control command conversion module:

[0095] Stopper initialization: At the beginning of the control command conversion, the stopper is first initialized, which usually means lowering the stopper to the lower limit of its mechanical structure so that the stopper is in a known and safe starting state.

[0096] Control Strategy Analysis: Next, the control command conversion module will analyze the control strategy output by the control measurement matching unit. The strategy is formulated based on the installation position of the stop and the specific requirements of the conveyor line, aiming to optimize the action sequence and timing of the stop.

[0097] Control information generation: After parsing the control strategy, the control command conversion module will generate corresponding control information according to the specific requirements of the strategy. The control information usually includes start signal, direction signal, speed command, etc., which will directly guide the action of the stop.

[0098] Information transmission: Finally, the control command conversion module will send the generated control information to the stop's execution unit (such as a DC brushless motor driver) to drive the stop to act according to the predetermined strategy.

[0099] Improving motion accuracy: By translating control strategies into specific control information, the control command conversion module enables the stopper's actions to align with the overall requirements of the conveyor line, thereby improving motion accuracy.

[0100] Improve system flexibility: Since the control strategy is pre-set and can be adjusted according to actual needs, the control command conversion module can flexibly respond to different work scenarios and requirements, thereby improving the adaptability and flexibility of the entire system.

[0101] Enhanced system stability: Through precise control command conversion, the system can more effectively manage the movement of the stop, reducing malfunctions and downtime caused by misoperation or improper operation, thereby enhancing the stability and reliability of the system.

[0102] In summary, the control command conversion module plays a crucial role in the electrical system of the high-speed stop device in a high-speed roller conveyor. By analyzing the control strategy and generating corresponding control information, it enables the stop device to execute actions accurately and efficiently in a predetermined manner, providing a strong guarantee for the smooth operation of the entire conveyor line.

[0103] The control command execution unit sends control information to the DC brushless motor driver of the stop. The control information includes a start signal and a direction signal. The start signal and the direction signal control the DC brushless motor driver of the stop to make the DC brushless motor rotate forward and backward, thereby driving the stop baffle to move up and down.

[0104] The control command execution unit plays a core role in the electrical system of the high-speed stop device in a high-speed roller conveyor. It is responsible for accurately transmitting the control information generated by the control command conversion module to the DC brushless motor driver of the stop device, thereby controlling the movement of the stop device. The specific functions and importance of the control command execution unit are as follows:

[0105] The control command execution unit first receives control information from the control command conversion module. This control information includes start signals, direction signals, etc., which describe in detail how the stop should operate. After receiving the information, the control command execution unit parses it to accurately understand the control intent.

[0106] After parsing the control information, the control command execution unit sends these signals to the DC brushless motor driver of the stop. The DC brushless motor driver is the key device for controlling the movement of the stop; it controls the forward and reverse rotation of the DC brushless motor based on the received signals.

[0107] The start signal is used to activate the motor driver, preparing it to perform actions; the direction signal determines the direction of motor rotation, thereby controlling the rise or fall of the stop plate.

[0108] While sending signals, the control command execution unit also monitors the execution of the DC brushless motor driver to ensure that the stop moves accurately according to the predetermined strategy.

[0109] If an abnormality or malfunction occurs during execution, the control command execution unit will respond promptly, including stopping the current action, issuing an alarm, or performing other error handling operations.

[0110] The control command execution unit is the final step in realizing the control strategy; it directly controls the movement of the stop. If the execution unit malfunctions or fails, the entire control process will not achieve the desired effect.

[0111] Since the control command execution unit is directly connected to the drive device of the stop, it can respond to control commands quickly, enabling the stop to complete its action in the shortest possible time, which is crucial for improving the overall operating efficiency of the conveyor line.

[0112] Through a rigorous signal transmission and monitoring mechanism, the control command execution unit ensures the accuracy and stability of the stop's action. Simultaneously, it possesses error handling capabilities, which can reduce the system failure rate and improve the overall system reliability to a certain extent.

[0113] In summary, the control command execution unit is an indispensable part of the electrical system of the high-speed stop device in a high-speed roller conveyor. By accurately receiving, parsing, and executing control information, it enables the stop device to operate efficiently and stably according to a predetermined strategy, providing a strong guarantee for the smooth operation of the conveyor line.

[0114] Specifically, the electrical system for a high-speed stopper device in a high-speed roller conveyor line according to the present invention includes a stopper coupled with a linear segment control strategy, comprising:

[0115] After the stop control starts, initialization is performed first. The stop descends to the lower limit and the wave of the straight segment controlled by the host computer is checked. If it is wave collection control, it is checked whether the current station is releasing boxes. If not, the stop rises to the upper limit. If the current station is releasing boxes, the stop rises to the upper limit after the turnover box leaves the current station's accumulation and reaches the next station's accumulation. Then, after the current station finishes entering the box and encounters the stop's calibration position, the stop is detected to be in the raised state, and the current station stops the box release. Wave collection is completed. If it is wave release, the host computer controls the stop to release the wave. After the stop descends to the lower limit, the current station's accumulation detects that the stop has descended completely, and the current station's turnover box is released. Wave release control is completed, and the stop control combined with the straight segment control ends.

[0116] In high-speed roller conveyor lines, the control strategy of using stoppers in conjunction with straight sections is key to ensuring accurate stopping and smooth flow of goods during transport. Specifically, this control strategy includes the following steps:

[0117] After the stop control starts, an initialization operation is performed first, which means that the stop will be lowered to the lower limit of its mechanical structure, so that it is in a known and safe starting state.

[0118] Next, the system will determine the control sequence of the host computer on the straight segment. Sequence control is a common scheduling method in logistics automation, used to optimize the order of goods leaving and entering boxes.

[0119] If the current setting is "collection control", the system will further check whether the accumulated goods at this station (i.e., the current workstation's goods storage area) are being shipped out.

[0120] Wavelet control: Under wavelet control, if the current station's stack is not in the outgoing state, the stop will immediately rise to the upper limit to prepare for the next incoming operation. If the current station's stack is in the outgoing state, the system will wait for the turnover box (the box loaded with goods) to leave the current station's stack and arrive at the next station's stack before raising the stop to the upper limit.

[0121] Once the box-in operation at this station is completed, the turnover box will encounter the calibration position of the stop. At this time, the system will detect the raised state of the stop and stop the box-out operation at this station, thus completing the wave control.

[0122] Release wave control: If the current setting is "Release Wave Control," the host computer will send a command to control the stop to perform a wave release operation. The stop will descend to its lower limit, making room for the goods to exit the container. Once the station detects that the stop has descended, it will allow the container to exit, and the wave release control will be complete.

[0123] Once control is complete, whether it's wave-based control or wave-based release control, the stopper-line segment control strategy ends after the corresponding operation is performed.

[0124] This control strategy allows the system to flexibly adjust the position of the stoppers according to different wave requirements, ensuring accurate stopping and smooth flow of goods on straight sections. Simultaneously, the strategy also considers optimizing the order of goods entering and leaving the container, contributing to improved overall conveyor line efficiency.

[0125] Specifically, the electrical system for a high-speed stopper device in a high-speed roller conveyor line, as described in this invention, includes a control strategy for the stopper in conjunction with the transfer machine's box-out section, comprising:

[0126] After the control of the box-out stopper in the transfer section starts, initialization is performed first. The stopper descends to the lower limit position, the previous station's turnover box is discharged, and the current station's transfer section accumulates and sends in a straight box. The host computer command is retrieved to determine whether the turnover box has been transported to the straight section for accumulation. If not, it is determined whether the next station's accumulation section allows the box to enter. If the box is allowed to enter, the current station's turnover box is discharged to the next station. If the turnover box needs to be transported to the straight section for accumulation, the stopper rises to the upper limit position. After the current station's turnover box reaches the stopper calibration position, it is determined whether the accumulation section for accumulation allows the box to enter. If the box is allowed to enter, the current station's transfer box is discharged to the straight section for accumulation, and then the stopper descends to the lower limit position. The control of the box discharge by the stopper and the transfer section ends.

[0127] In high-speed roller conveyor lines, when stoppers are used in conjunction with transfer machines, especially in the box-exit section, a sophisticated control strategy is required to ensure that the boxes are accurately and efficiently transported to their designated locations. The following are the specific steps of the control strategy for stoppers combined with transfer machines in the box-exit section:

[0128] Initialization: After the control strategy starts, initialization is performed first. The stop is lowered to the lower limit, putting it in its initial state and ready to start working.

[0129] Unloading from the previous station's container: Immediately following, the container from the previous station begins unloading, preparing for the next stage of transport.

[0130] The transfer section of this station begins straight-line container loading: At the same time as the containers are being loaded from the previous station, the transfer section of this station begins straight-line container loading operations, that is, receiving containers from the previous station or preparing to receive new containers.

[0131] Retrieve instructions from the host computer and determine the destination of the turnover box: The system will retrieve instructions sent by the host computer to determine the current destination of the turnover box. If the turnover box does not need to be transported to the straight section for stacking, proceed to the next step of judgment.

[0132] Determining if the next station's accumulation section allows the container to enter: If the container is not transported to the transfer and exit straight section, the system will check if the next station's accumulation section allows the container to enter. If allowed, the container will be directly exited to the next station.

[0133] Stopper rises to upper limit to prepare for box receiving: If the turnover box needs to be transported to the straight section for transfer and exit, the stopper will rise to the upper limit to prepare for the accurate stopping position of the turnover box.

[0134] Turnover box in place and calibrated position: After the turnover box is in place, it will encounter the calibration position of the stop, so that the turnover box is accurately stopped in the predetermined position.

[0135] Determine if the backlog of the container being transferred out is allowed to be loaded into the container: The system checks again whether the backlog of the container being transferred out is allowed to be loaded into the container to confirm the safety of the next operation.

[0136] The station will use a transfer machine to transport the turnover boxes to the straight section from the box transfer point to the box transfer point. If the accumulation of the box transfer point allows for the entry of new boxes, the station will use a transfer machine to transport the turnover boxes to the accumulation area of ​​the straight section from the box transfer point to the box transfer point.

[0137] The stopper descends to the lower limit and ends the control: After the turnover box is successfully transported to the transfer and unloading straight section, the stopper will descend to the lower limit, completing the control process of this unloading operation.

[0138] This control strategy allows the stopper and transfer machine to work closely together, ensuring efficient and accurate transport of the turnover boxes in the box-out section. At the same time, this strategy also considers the overall operating efficiency and safety of the conveyor line, preventing production delays or accidents caused by inaccurate box positioning or poor transport.

[0139] Specifically, the electrical system for a high-speed stopper device in a high-speed roller conveyor line, as described in this invention, includes a control strategy for the stopper in conjunction with the transfer machine's box-entry section, comprising:

[0140] After the stopper is used in conjunction with the transfer machine's box entry section control, it is initialized first. The left stopper descends to the lower limit, and the right stopper descends to the lower limit.

[0141] Determine the direction of the transfer machine entering the container. If it is moving straight into the container, after the container is in place at this station, determine whether the next station's storage section allows the container to enter. If it is allowed, the container will be moved from this station to the next station's storage section.

[0142] If the left-hand box is being transferred, the left stop will descend to the lower limit and the right stop will rise to the upper limit. Then, it will be determined whether the left stop has descended to the lower limit. After the left stop has descended to the lower limit, the turnover box will be transported from the left-hand box transfer straight section to the current station's storage. After encountering the right stop baffle, the position will be calibrated. After the current station's turnover box has entered the storage position, both the left and right stops will descend to the lower limit. After both have descended to the lower limit, it will be determined whether the next station's storage section allows the box to enter. If the box is allowed to enter, the current station's turnover box will exit to the next station's storage.

[0143] If the transfer box is entering from the right, the right stop will descend to the lower limit and the left stop will rise to the upper limit. Then, it will be determined whether the right stop has descended to the lower limit. After the right stop has descended to the lower limit, the turnover box will be transported from the transfer box entering from the right to the straight section to the current station for storage. After the turnover box touches the left stop baffle, its position will be adjusted. After the turnover box enters the current station, both the left and right stops will descend to the lower limit. After both have descended to the lower limit, it will be determined whether the next station for storage is allowed to enter the box. If the turnover box is allowed to enter, the turnover box will exit the current station for storage at the next station. The control of the stop and the transfer machine section for the turnover box entering the box ends.

[0144] In high-speed roller conveyor lines, when stoppers are used in conjunction with transfer machines in the box-feeding section, a sophisticated control strategy is required to ensure that the boxes can accurately and efficiently enter the designated positions. The following are the specific steps of the control strategy for stoppers combined with transfer machines in the box-feeding section:

[0145] Initialization: After the control strategy starts, the initialization operation is performed first. Both the left and right stoppers will descend to their lower limit positions, which is their initial state, ready to start working.

[0146] Determine the direction of the transfer machine entering the container: Next, the system will determine the direction of the transfer machine entering the container, which determines how the container will be transported to the storage area of ​​this station.

[0147] Straight-line container entry processing: If the transfer machine enters the container in a straight line, meaning the container is transported directly to this station, the system will determine whether the next station's accumulation section allows the container to enter once it arrives. If allowed, the container will be moved from this station to the next station's accumulation area.

[0148] Left-in container transfer processing: If the transfer machine uses a left-in container transfer mechanism, meaning the container is transported from the left side to this station, the control strategy will first lower the left stop to its lower limit while simultaneously raising the right stop to its upper limit. Then, the system will determine if the left stop has reached its designated position. Once the left stop is in position, the container will be transported from the left-in container transfer section to the station's accumulation area. When the container encounters the right stop, the system will calibrate its position to ensure accurate stopping. Afterward, both the left and right stops will lower to their lower limits. Finally, the system will again determine if the next accumulation section allows container entry; if so, the container will be moved from this station to the next station.

[0149] Right-in container transfer: If the transfer machine uses a right-in container transfer mechanism, meaning the container is transported from the right side to this station, the process is similar to that for left-in containers, but the stop mechanisms operate in the opposite direction. The right stop mechanism first descends to its lower limit, while the left stop mechanism rises to its upper limit. Then, the system determines whether the right stop mechanism has descended to its correct position and controls the transport and alignment of the container accordingly. Finally, both stops descend to their lower limits, and the system determines the container entry conditions for the next station.

[0150] End of control: Regardless of which direction the container enters the station from, once it successfully exits to the next station's storage area, the stop device combined with the transfer machine's container entry control strategy will end, awaiting the next container entry operation.

[0151] Through this control strategy, the stopper and the transfer machine can work closely together to ensure the efficient and accurate transport of the turnover boxes in the box-in section. This strategy not only improves the overall operating efficiency of the conveyor line, but also enhances the flexibility and adaptability of the system, enabling it to meet the box-in requirements of different directions and conditions.

[0152] Specifically, the electrical system for a high-speed stopper device in a high-speed roller conveyor line, as described in this invention, includes a stopper paired with a control strategy for the box-out section of a swing wheel machine, comprising:

[0153] After the stopper and the balance wheel machine box-out control start, initialization is performed first. The balance wheel machine turns to the straight-line direction, the stopper descends to the lower limit, the previous station's turnover box is discharged, and the current station's transfer section accumulates and moves straight into the box. The host computer command is retrieved to determine whether the turnover box has been transported to the balance wheel machine's box-out straight section for accumulation. If not, it is determined whether the next station's accumulation section allows box entry. If box entry is allowed, the balance wheel machine turns to the straight-line box-out direction, and the current station's turnover box is discharged to the next station. If the turnover box needs to be transported to the balance wheel machine's box-out straight section for accumulation, the stopper rises to the upper limit. After the current station's turnover box reaches the stopper calibration position, the balance wheel machine turns to the balance wheel branch box-out direction. It is determined whether the balance wheel branch box-out section's accumulation section allows box entry. If box entry is allowed, the current station's balance wheel machine discharges the box to the balance wheel machine's branch box-out straight section, and then the stopper descends to the lower limit. The stopper and balance wheel machine box-out control ends.

[0154] In high-speed roller conveyor lines, when stoppers are used in conjunction with a swing wheel mechanism in the box-out section, a sophisticated control strategy is required to ensure that the boxes are accurately and efficiently transported to the designated location. The following are the specific steps of the control strategy for the box-out section using stoppers and swing wheel mechanisms:

[0155] Initialization: After the control strategy starts, initialization is performed first. The balance wheel mechanism turns to the straight-line direction to prepare for the transport of the turnover box. At the same time, the stop lowers to the lower limit, which is also its initial state.

[0156] The previous station's turnover boxes are shipped out and transported to this station along the conveyor line. The turnover boxes in this station's transfer section will then move directly into the accumulation area, meaning they will travel in a straight line.

[0157] Determining the destination of the turnover box: The system will retrieve the instructions from the host computer to determine whether the turnover box needs to be transported to the straight section of the exit of the swing wheel machine for accumulation. This determination is based on the current transportation task and the destination requirements.

[0158] If the container does not need to be transported to the straight section of the balance wheel machine's outlet: If the container does not need to be transported to the straight section of the balance wheel machine's outlet, the system will continue to determine whether the next station's accumulation section allows the container to enter. If allowed, the balance wheel machine will turn to the straight-line outlet direction, and then the container from this station will exit to the next station's accumulation area.

[0159] If the container needs to be transported to the straight section of the balance wheel machine's outlet: If the container needs to be transported to the straight section of the balance wheel machine's outlet, the stop will rise to its upper limit to prepare for the container's accurate stopping position. When the container is in place, it will encounter the stop's calibration position, ensuring the container stops accurately in the designated location.

[0160] Balance wheel machine steering and branch box discharge judgment: After the turnover box is parked in place, the balance wheel machine will turn to the branch box discharge direction, preparing to transport the turnover box to the straight section of the balance wheel machine's branch box discharge. At this time, the system will again judge whether the accumulation in the branch box discharge section of the balance wheel machine allows for box entry, so as to ensure the smooth operation of the conveyor line.

[0161] Balance wheel machine box ejection and stopper reset: If the accumulation in the balance wheel branch box ejection section allows for box entry, the balance wheel machine will eject the turnover box to the balance wheel machine branch box ejection straight section. After ejection is completed, the stopper will descend to the lower limit, returning to its initial state, waiting for the next control command.

[0162] Control End: This concludes the control strategy for the stopper combined with the balance wheel conveyor at the box outlet. Throughout the process, the system, through precise control and judgment, ensured the accurate and efficient transport of the turnover boxes on the high-speed roller conveyor line.

[0163] This control strategy fully considers the coordinated operation of the balance wheel and the stop, as well as the needs of different accumulation sections on the conveyor line. Through real-time monitoring and flexible adjustments, the system can handle complex conveying tasks and improve the overall operating efficiency and stability of the conveyor line.

[0164] Secondly, the present invention provides a control method for a high-speed stop device in a high-speed roller conveyor line, applied to the electrical system of the high-speed stop device in the high-speed roller conveyor line, comprising:

[0165] Step S101: Obtain the stop device information and the stop device installation location information;

[0166] Step S102: Match the stopper installation position information in the preset control strategy knowledge base to obtain the control strategy corresponding to the stopper installation position. The control strategy knowledge base includes the stopper with straight section control strategy, the stopper with transfer machine box exit section control strategy, the stopper with transfer machine box entry section control strategy, and the stopper with swing wheel machine box exit section control strategy.

[0167] Step S103: Initialize the stopper. When the stopper descends to the lower limit, convert the control strategy corresponding to the installation position of the stopper into control information.

[0168] Step S104: Send control information to the DC brushless motor driver of the stop. The control information includes a start signal and a direction signal. The start signal and the direction signal control the DC brushless motor driver of the stop to make the DC brushless motor rotate forward and backward, thereby driving the stop baffle to move up and down.

[0169] Specifically, in the control method for a high-speed stop device in a high-speed roller conveyor line according to the present invention, step S102 includes:

[0170] The stopper combined with the linear segment control strategy includes initialization after the stopper control starts. The stopper descends to the lower limit and the host computer controls the linear segment wave. If it is wave collection control, it checks whether the current station is releasing boxes. If not, the stopper rises to the upper limit. If the current station is releasing boxes, the stopper rises to the upper limit after the box leaves the current station and reaches the next station. Then, after the current station finishes receiving boxes and encounters the stopper calibration position, it detects the stopper's raised state and stops the current station's box release, completing the wave collection. If it is a wave release, the host computer controls the stopper to release the wave. After the stopper descends to the lower limit, the current station detects the stopper's descent is complete, and the current station releases the box, completing the wave release control. The stopper combined with the linear segment control ends.

[0171] Specifically, in the control method for a high-speed stop device in a high-speed roller conveyor line according to the present invention, step S102 includes:

[0172] The control strategy for the stopper combined with the transfer machine's box-out section includes the following steps: After the stopper control for the box-out section begins, initialization is performed. The stopper descends to the lower limit, the previous station's turnover box is discharged, and the current station's transfer section accumulates and moves straight into the box. The host computer's instructions are retrieved to determine whether the turnover box has been transported to the straight section for accumulation. If not, it is determined whether the next station's accumulation section allows box entry. If box entry is allowed, the current station's turnover box is discharged to the next station. If the turnover box needs to be transported to the straight section for accumulation, the stopper rises to the upper limit. After the current station's turnover box reaches the stopper's calibration position, it is determined whether the transfer section's accumulation section allows box entry. If box entry is allowed, the current station's transfer box is discharged to the straight section for accumulation, and then the stopper descends to the lower limit. The stopper combined with the transfer machine's box-out section control ends.

[0173] Specifically, in the control method for a high-speed stop device in a high-speed roller conveyor line according to the present invention, step S102 includes:

[0174] The control strategy for the stopper combined with the transfer machine entering the box section includes initialization after the stopper combined with the transfer machine entering the box section control starts, the left stopper descends to the lower limit, and the right stopper descends to the lower limit.

[0175] Determine the direction of the transfer machine entering the container. If it is moving straight into the container, after the container is in place at this station, determine whether the next station's storage section allows the container to enter. If it is allowed, the container will be moved from this station to the next station's storage section.

[0176] If the left-hand box is being transferred, the left stop will descend to the lower limit and the right stop will rise to the upper limit. Then, it will be determined whether the left stop has descended to the lower limit. After the left stop has descended to the lower limit, the turnover box will be transported from the left-hand box transfer straight section to the current station's storage. After encountering the right stop baffle, the position will be calibrated. After the current station's turnover box has entered the storage position, both the left and right stops will descend to the lower limit. After both have descended to the lower limit, it will be determined whether the next station's storage section allows the box to enter. If the box is allowed to enter, the current station's turnover box will exit to the next station's storage.

[0177] If the transfer box is entering from the right, the right stop will descend to the lower limit and the left stop will rise to the upper limit. Then, it will be determined whether the right stop has descended to the lower limit. After the right stop has descended to the lower limit, the turnover box will be transported from the transfer box entering from the right to the straight section to the current station for storage. After the turnover box touches the left stop baffle, its position will be adjusted. After the turnover box enters the current station, both the left and right stops will descend to the lower limit. After both have descended to the lower limit, it will be determined whether the next station for storage is allowed to enter the box. If the turnover box is allowed to enter, the turnover box will exit the current station for storage at the next station. The control of the stop and the transfer machine section for the turnover box entering the box ends.

[0178] Specifically, in the control method for a high-speed stop device in a high-speed roller conveyor line according to the present invention, step S102 includes:

[0179] The control strategy for the box-out section of the stopper combined with the balance wheel machine includes the following steps: After the control starts, initialization is performed, the balance wheel machine turns to the straight-line direction, the stopper descends to the lower limit, the previous station's turnover box is discharged, and the current station's transfer section accumulates and moves straight-line into the box. The system retrieves instructions from the host computer to determine if the turnover box has been transported to the straight-line section of the balance wheel machine for accumulation. If not, it determines whether the next station's accumulation section allows box entry. If box entry is allowed, the balance wheel machine turns to the straight-line direction for box discharge. Afterwards, the turnover box from this station is sent to the next station. If the turnover box needs to be transported to the straight section of the balance wheel machine for accumulation, the stop will rise to the upper limit. After the turnover box from this station is in place and hits the stop calibration position, the balance wheel machine will turn to the direction of the balance wheel branch exit. It will then determine whether the accumulation of the balance wheel branch exit section is allowed to enter the box. If it is allowed, the balance wheel machine from this station will exit the box to the straight section of the balance wheel machine branch exit. Then the stop will descend to the lower limit. The stop and the balance wheel machine section exit control will then end.

[0180] like Figure 2As shown, the stop is installed between the last electric roller accumulating on the straight section of this station and the first electric roller accumulating on the straight section of the next station.

[0181] like Figure 3 As shown, after the straight-line stop control starts, initialization is performed first, and the stop descends to the lower limit. The control of the straight-line segment wave is then determined by the host computer. If it's a wave collection control, it checks if the current station is releasing boxes. If not, the stop rises to the upper limit. If it is releasing boxes, the stop rises to the upper limit after the box leaves the current station and reaches the next station. Then, after the current station finishes receiving boxes and encounters the stop's calibration position, it detects the stop's raised state and stops the current station's box release, completing the wave collection. If it's a wave release, the host computer controls the stop to release the wave. After the stop descends to the lower limit, the current station detects the stop's descent is complete, and the current station releases the box, completing the wave release control. The stop control combined with the straight-line segment control ends.

[0182] like Figure 4 As shown, the stop is installed between the last electric roller in the transfer machine section of this station and the first electric roller in the straight section of the next station.

[0183] like Figure 5 As shown, after the control of the box-out stop in the transfer section starts, initialization is performed first, and the stop descends to the lower limit. The previous station's turnover box is discharged, and the current station's transfer section accumulates and sends in a straight-line box. The host computer command is retrieved to determine if the turnover box has been transported to the straight-line accumulation section for box discharge. If not, it is determined whether the next station's accumulation section allows box entry. If entry is allowed, the current station's turnover box is discharged to the next station. If the turnover box needs to be transported to the straight-line accumulation section for box discharge, the stop rises to the upper limit. After the current station's turnover box reaches its position, it touches the stop's calibration position. It is then determined whether the accumulation section for box discharge allows box entry. If entry is allowed, the current station's box is discharged to the straight-line accumulation section for box discharge, and then the stop descends to the lower limit. The stop, in conjunction with the transfer section's box discharge control, ends.

[0184] like Figure 6 As shown, the stop for the left inlet box of the transfer machine is installed between the right side of the accumulation line of the transfer machine section and the first electric roller of the straight section of the right inlet box of the transfer machine. The stop for the right inlet box of the transfer machine is installed between the left side of the accumulation line of the transfer machine section and the first electric roller of the straight section of the left inlet box of the transfer machine.

[0185] like Figure 7 As shown, after the stopper is used in conjunction with the transfer machine's box entry section control, it is initialized first. The left stopper descends to the lower limit, and the right stopper descends to the lower limit.

[0186] Determine the direction of the transfer machine entering the container. If it is moving straight into the container, after the container is in place at this station, determine whether the next station's accumulation section allows the container to enter. If it is allowed, the container will be moved from this station to the next station's accumulation section.

[0187] If the left-hand entry box is being transferred, the left stop will descend to the lower limit, and the right stop will rise to the upper limit. Then, it will be checked whether the left stop has descended to the lower limit. After the left stop has descended to the lower limit, the turnover box will be transported from the left-hand entry box section to the current station's storage area. After encountering the right stop baffle, the position will be adjusted. After the current station's turnover box has entered the storage area, both the left and right stops will descend to the lower limit. After both have descended to the lower limit, it will be checked whether the next storage area is allowed to receive the box. If the box is allowed to receive the box, the current station's turnover box will be discharged to the next storage area.

[0188] If the transfer box is moving in from the right, the right stop lowers to its lower limit, and the left stop rises to its upper limit. Then, it checks if the right stop has lowered to its lower limit. Once the right stop is in place, the box is transported from the right-hand transfer section to the current storage station. After encountering the left stop, its position is adjusted. Once the box is in place at the current station, both the left and right stops lower to their lower limits. After both are in place, it checks if the next storage station allows box entry. If entry is allowed, the box exits to the next storage station. The control of the stop mechanism in conjunction with the transfer machine section ends.

[0189] like Figure 8 As shown, the stop is installed between the last electric roller in the transfer machine section of this station and the first electric roller in the straight section of the next station.

[0190] like Figure 9 As shown, after the stopper and the balance wheel machine's box-out control begin, initialization is performed first. The balance wheel machine turns to the straight-line direction, and the stopper descends to the lower limit. The previous station's turnover box is discharged, and the current station's transfer section accumulates boxes in a straight-line manner. The host computer's instructions are retrieved to determine if the turnover box has been transported to the balance wheel machine's box-out straight-line section for accumulation. If not, it is determined whether the next station's accumulation section allows box entry. If box entry is allowed, the balance wheel machine turns to the straight-line box-out direction, and the current station's turnover box is discharged to the next station. If the turnover box needs to be transported to the balance wheel machine's box-out straight-line section for accumulation, the stopper rises to the upper limit. After the current station's turnover box reaches the stopper's calibration position, the balance wheel machine turns to the balance wheel branch box-out direction. It is determined whether the balance wheel branch box-out section's accumulation section allows box entry. If box entry is allowed, the current station's balance wheel machine discharges the box to the balance wheel machine's branch box-out straight-line section, and then the stopper descends to the lower limit. The stopper and balance wheel machine's box-out control ends.

[0191] The technical solution of this invention solves the problems of slow cycle time and instability when the stopper is applied to a high-speed conveyor line in the following way:

[0192] Power Source Replacement: Traditional stoppers typically use cylinders as their power source, and their lifting speed and operating cycle are highly dependent on the stability of the air pressure. On high-speed conveyor lines, this dependence leads to slow and unstable stopper operation. This invention uses a brushless DC motor as the power source for the stopper. This motor has a faster response speed and higher stability, meeting the requirements of high-speed conveyor lines for fast and accurate stopper operation.

[0193] Electrical System and Control Method Design: This invention provides a specialized electrical system including a controller, an ASI gateway, an ASI electric roller drive module, a proximity switch, and a DC brushless motor driver. These components work together to achieve precise control of the stop. The controller integrates a data acquisition unit, a control measurement matching unit, a control command conversion unit, and a control command execution unit. These units can generate corresponding control information based on the stop's installation position and a preset control strategy, and control the stop's movement through the DC brushless motor driver.

[0194] Pre-set Control Strategy Knowledge Base: This invention pre-sets a control strategy knowledge base in the controller, including control strategies for stoppers paired with straight sections, stoppers paired with transfer machine exit sections, stoppers paired with transfer machine entry sections, and stoppers paired with swing wheel machine exit sections. These control strategies are optimized for different conveyor line scenarios, improving the cycle time and stability of the operation while ensuring the accuracy of the stopper's action.

[0195] Real-time monitoring and feedback: This invention monitors the position of the stop in real time through upper and lower limit proximity switches, ensuring that the stop remains in the correct position during operation. Simultaneously, the DC brushless motor driver feeds back fault signals to the ASI electric roller drive module, allowing the controller to adjust its control strategy promptly based on this feedback information, thus ensuring stable operation of the stop.

[0196] In summary, this invention effectively solves the problems of slow and unstable cycle time when the stopper is applied to a high-speed conveyor line by changing the power source, designing a dedicated electrical system and control method, pre-setting a control strategy knowledge base, and implementing real-time monitoring and feedback.

[0197] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from the spirit and scope of this invention. If these modifications and variations of this invention fall within the scope of the claims of this invention and their equivalents, then this invention also intends to include these modifications and variations. The above-described embodiments of this invention do not constitute a limitation on the scope of protection of this invention.

Claims

1. An electrical system for a high-speed stop device in a high-speed roller conveyor line, characterized in that, include: Controller, ASI gateway, ASI electric roller drive module, upper limit proximity switch, lower limit proximity switch, brushless DC motor driver and stopper brushless DC motor; The controller establishes a communication connection with the ASI gateway. The ASI gateway connects to the distributed ASI electric roller drive module via the ASI bus. The ASI electric roller drive module connects to the upper limit proximity switch and the lower limit proximity switch, receives the DC brushless motor driver fault signal, and sends the DC brushless motor driver fault signal input signal to the ASI electric roller drive module. The ASI electric roller drive module outputs start signal and direction signal to control the DC brushless motor driver, which is used to make the DC brushless motor rotate forward and reverse, thereby driving the stop baffle to move up and down. The controller includes: The data acquisition unit acquires information about the stopper device and its installation location. The control measurement matching unit matches the stopper installation position information with the preset control strategy knowledge base to obtain the control strategy corresponding to the stopper installation position. The control strategy knowledge base includes the stopper paired with the straight section control strategy, the stopper paired with the transfer machine exit section control strategy, the stopper paired with the transfer machine inlet section control strategy, and the stopper paired with the swing wheel machine exit section control strategy. The control command conversion unit initializes the stopper and lowers it to the lower limit position, converting the control strategy corresponding to the installation position of the stopper into control information. The control command execution unit sends control information to the DC brushless motor driver of the stop. The control information includes a start signal and a direction signal. The start signal and the direction signal control the DC brushless motor driver of the stop to make the DC brushless motor rotate forward and backward, thereby driving the stop baffle to move up and down.

2. The electrical system for a high-speed stop device in a high-speed roller conveyor line as described in claim 1, characterized in that, The stopper is paired with a straight-segment control strategy, including: After the stop control starts, initialization is performed first. The stop descends to the lower limit and the wave of the straight segment controlled by the host computer is checked. If it is wave collection control, it is checked whether the current station is releasing boxes. If not, the stop rises to the upper limit. If the current station is releasing boxes, the stop rises to the upper limit after the turnover box leaves the current station's accumulation and reaches the next station's accumulation. Then, after the current station finishes entering the box and encounters the stop's calibration position, the stop is detected to be in the raised state, and the current station stops the box release. Wave collection is completed. If it is wave release, the host computer controls the stop to release the wave. After the stop descends to the lower limit, the current station's accumulation detects that the stop has descended completely, and the current station's turnover box is released. Wave release control is completed, and the stop control combined with the straight segment control ends.

3. The electrical system for a high-speed stop device in a high-speed roller conveyor line as described in claim 1, characterized in that, The stopper, combined with the transfer machine's box-out section control strategy, includes: After the control of the box-out stopper in the transfer section starts, initialization is performed first. The stopper descends to the lower limit position, the previous station's turnover box is discharged, and the current station's transfer section accumulates and moves straight into the box. The host computer command is retrieved to determine whether the turnover box has been transported to the straight section for accumulation. If not, it is determined whether the next station's accumulation section allows box entry. If box entry is allowed, the current station's turnover box is discharged to the next station. If the turnover box needs to be transported to the straight section for accumulation, the stopper rises to the upper limit position. After the current station's turnover box reaches the stopper calibration position, it is determined whether the accumulation section for accumulation allows box entry. If box entry is allowed, the current station's transfer box is discharged to the straight section for accumulation, and then the stopper descends to the lower limit position. The control of the box discharge section in conjunction with the stopper and the transfer machine ends.

4. The electrical system for a high-speed stop device in a high-speed roller conveyor line as described in claim 1, characterized in that, The stopper, combined with the transfer machine's inlet section control strategy, includes: After the stopper is used in conjunction with the transfer machine's box entry section control, it is initialized first. The left stopper descends to the lower limit, and the right stopper descends to the lower limit. Determine the direction of the transfer machine entering the container. If it is moving straight into the container, after the container is in place at this station, determine whether the next station's storage section allows the container to enter. If it is allowed, the container will be moved from this station to the next station's storage section. If the left-hand box is being transferred, the left stop will descend to the lower limit and the right stop will rise to the upper limit. Then, it will be determined whether the left stop has descended to the lower limit. After the left stop has descended to the lower limit, the turnover box will be transported from the left-hand box transfer straight section to the current station's storage. After encountering the right stop baffle, the position will be calibrated. After the current station's turnover box has entered the storage position, both the left and right stops will descend to the lower limit. After both have descended to the lower limit, it will be determined whether the next station's storage section allows the box to enter. If the box is allowed to enter, the current station's turnover box will exit to the next station's storage. If the transfer box is entering from the right, the right stop will descend to the lower limit and the left stop will rise to the upper limit. Then, it will be determined whether the right stop has descended to the lower limit. After the right stop has descended to the lower limit, the turnover box will be transported from the transfer box entering from the right to the station's storage section. After the turnover box touches the left stop baffle, its position will be adjusted. After the turnover box enters the station's storage section, both the left and right stops will descend to the lower limit. After both have descended to the lower limit, it will be determined whether the next station's storage section allows the turnover box to enter. If the turnover box is allowed to enter, the turnover box will exit the station's storage section and enter the next station. The control of the turnover box entering the section with the stop and the transfer machine will end.

5. The electrical system for a high-speed stop device in a high-speed roller conveyor line as described in claim 1, characterized in that, The stopper combined with the control strategy for the exit section of the balance wheel mechanism includes: After the stopper and the balance wheel machine box-out control start, initialization is performed first. The balance wheel machine turns to the straight-line direction, the stopper descends to the lower limit, the previous station's turnover box is discharged, and the current station's transfer section accumulates and moves straight into the box. The host computer command is retrieved to determine whether the turnover box has been transported to the balance wheel machine's box-out straight-line section for accumulation. If not, it is determined whether the next station's accumulation section allows box entry. If box entry is allowed, the balance wheel machine turns to the straight-line box-out direction, and the current station's turnover box is discharged to the next station. If the turnover box needs to be transported to the balance wheel machine's box-out straight-line section for accumulation, the stopper rises to the upper limit. After the current station's turnover box reaches the stopper calibration position, the balance wheel machine turns to the balance wheel branch box-out direction. It is determined whether the balance wheel branch box-out section's accumulation section allows box entry. If box entry is allowed, the current station's balance wheel machine discharges the box to the balance wheel machine's branch box-out straight-line section, and then the stopper descends to the lower limit. The stopper and balance wheel machine box-out control ends.

6. A control method for a high-speed stop device in a high-speed roller conveyor line, applied to the electrical system for a high-speed stop device in a high-speed roller conveyor line as described in any one of claims 1 to 5, characterized in that, include: Step S101: Obtain the stop device information and the stop device installation location information; Step S102: Match the stopper installation position information in the preset control strategy knowledge base to obtain the control strategy corresponding to the stopper installation position. The control strategy knowledge base includes the stopper with straight section control strategy, the stopper with transfer machine box exit section control strategy, the stopper with transfer machine box entry section control strategy, and the stopper with swing wheel machine box exit section control strategy. Step S103: Initialize the stopper. When the stopper descends to the lower limit, convert the control strategy corresponding to the installation position of the stopper into control information. Step S104: Send control information to the DC brushless motor driver of the stop. The control information includes a start signal and a direction signal. The start signal and the direction signal control the DC brushless motor driver of the stop to make the DC brushless motor rotate forward and backward, thereby driving the stop baffle to move up and down.

7. The control method for a high-speed stop device in a high-speed roller conveyor line as described in claim 6, characterized in that, Step S102 includes: The stopper combined with the linear segment control strategy includes initialization after the stopper control starts. The stopper descends to the lower limit and the host computer controls the linear segment wave. If it is wave collection control, it checks whether the current station is releasing boxes. If not, the stopper rises to the upper limit. If the current station is releasing boxes, the stopper rises to the upper limit after the box leaves the current station and reaches the next station. Then, after the current station finishes receiving boxes and encounters the stopper calibration position, it detects the stopper's raised state and stops the current station's box release, completing the wave collection. If it is a wave release, the host computer controls the stopper to release the wave. After the stopper descends to the lower limit, the current station detects the stopper's descent is complete, and the current station releases the box, completing the wave release control. The stopper combined with the linear segment control ends.

8. The control method for a high-speed stop device in a high-speed roller conveyor line as described in claim 6, characterized in that, Step S102 includes: The control strategy for the stopper combined with the transfer machine's box-out section includes the following steps: After the stopper control for the box-out section begins, initialization is performed. The stopper descends to the lower limit, the previous station's turnover box is discharged, and the current station's transfer section accumulates and moves straight into the box. The host computer's instructions are retrieved to determine whether the turnover box has been transported to the straight section for accumulation. If not, it is determined whether the next station's accumulation section allows box entry. If box entry is allowed, the current station's turnover box is discharged to the next station. If the turnover box needs to be transported to the straight section for accumulation, the stopper rises to the upper limit. After the current station's turnover box reaches the stopper's calibration position, it is determined whether the transfer section's accumulation section allows box entry. If box entry is allowed, the current station's transfer box is discharged to the straight section for accumulation, and then the stopper descends to the lower limit. The control of the stopper combined with the transfer machine's box-out section ends.

9. The control method for a high-speed stop device in a high-speed roller conveyor line as described in claim 6, characterized in that, Step S102 includes: The control strategy for the stopper combined with the transfer machine entering the box section includes initialization after the stopper combined with the transfer machine entering the box section control starts, the left stopper descends to the lower limit, and the right stopper descends to the lower limit. Determine the direction of the transfer machine entering the container. If it is moving straight into the container, after the container is in place at this station, determine whether the next station's storage section allows the container to enter. If it is allowed, the container will be moved from this station to the next station's storage section. If the left-hand box is being transferred, the left stop will descend to the lower limit and the right stop will rise to the upper limit. Then, it will be determined whether the left stop has descended to the lower limit. After the left stop has descended to the lower limit, the turnover box will be transported from the left-hand box transfer straight section to the current station's storage. After encountering the right stop baffle, the position will be calibrated. After the current station's turnover box has entered the storage position, both the left and right stops will descend to the lower limit. After both have descended to the lower limit, it will be determined whether the next station's storage section allows the box to enter. If the box is allowed to enter, the current station's turnover box will exit to the next station's storage. If the transfer box is entering from the right, the right stop will descend to the lower limit and the left stop will rise to the upper limit. Then, it will be determined whether the right stop has descended to the lower limit. After the right stop has descended to the lower limit, the turnover box will be transported from the transfer box entering from the right to the station's storage section. After the turnover box touches the left stop baffle, its position will be adjusted. After the turnover box enters the station's storage section, both the left and right stops will descend to the lower limit. After both have descended to the lower limit, it will be determined whether the next station's storage section allows the turnover box to enter. If the turnover box is allowed to enter, the turnover box will exit the station's storage section and enter the next station. The control of the turnover box entering the section with the stop and the transfer machine will end.

10. The control method for a high-speed stop device in a high-speed roller conveyor line as described in claim 6, characterized in that, Step S102 includes: The control strategy for the box-out section of the stopper combined with the balance wheel machine includes the following steps: After the control starts, initialization is performed, the balance wheel machine turns to the straight-line direction, the stopper descends to the lower limit, the previous station's turnover box is discharged, and the current station's transfer section accumulates and moves straight-line into the box. The system retrieves instructions from the host computer to determine if the turnover box has been transported to the straight-line section of the balance wheel machine for accumulation. If not, it determines whether the next station's accumulation section allows box entry. If box entry is allowed, the balance wheel machine turns to the straight-line discharge direction. Moving backward, the turnover box from this station is dispatched to the next station. If the turnover box needs to be transported to the straight section of the balance wheel machine for accumulation, the stop will rise to the upper limit. After the turnover box reaches the stop calibration position, the balance wheel machine will turn to the direction of the balance wheel branch outlet box. It will then determine whether the accumulation of the balance wheel branch outlet box section is allowed to enter the box. If it is allowed, the balance wheel machine will dispatch the box to the straight section of the balance wheel machine branch outlet box, and then the stop will descend to the lower limit. The stop and balance wheel machine section box dispatch control ends.

Images