Automatic bag opening method, system and storage medium

Abstract

The present invention relates to the technical field of bag opening of packaging machines, and specifically to an automatic bag opening method, system and storage medium. The present invention can automatically complete the matching of the gas source size of the packaging machine with the customer's packaging bag by matching the gas source size with the current packaging bag and automatically adapting the gas source size to the packaging bag when the packaging bag does not match, thereby preventing the problem of packaging quality degradation due to unsuitable gas source size; by setting a bag opening abnormality detection network, when bag opening abnormality is detected during the normal operation of the packaging machine, multiple bag opening operations are performed to prevent bag opening abnormality caused by accidental factors; further, the present invention discovers bag opening failure problems by monitoring the number of times the bag is opened or the number of times the bag is discarded, and reminds the operator to deal with it in time to prevent unstable gas supply, leakage of gas supply pipe, loose suction cup and other further problems in bag opening quality.

Description

Technical Field

[0001] The invention relates to the technical field of bag opening of packaging machines, and in particular to an automatic bag opening method, system and storage medium. Background Art

[0002] Bag opening by packaging machine is an important part of the automated packaging process. It involves the process of automatically opening packaging materials (such as plastic bags, paper bags, aluminum foil bags, etc.) and preparing to fill the products. The quality of bag opening directly affects the subsequent filling and sealing effects. Therefore, during the packaging process, it is necessary to ensure the mechanical accuracy of the bag opening device and the stability of the control system to ensure the quality of bag opening. According to research, there are generally three reasons why the bag opening of the packaging machine cannot be completed normally: 1. The size of the customer's packaging bag does not match the air source of the packaging machine, resulting in the bag not being sucked up or multiple bags being sucked up at one time; 2. Abnormal bag opening caused by accidental factors such as quality problems of the packaging bag itself or dust on the packaging bag; 3. The air source is not stable when the packaging machine is just started. Summary of the invention

[0003] In view of this, the purpose of the present invention is to provide an automatic bag opening method, system and storage medium, which can automatically match the air source size corresponding to the packaging bag to ensure successful bag opening. At the same time, when the bag opening is unsuccessful, multiple bag opening methods are used to open the bag to prevent bag opening abnormalities caused by accidental factors. Finally, during the packaging operation of the packaging machine, the bag opening abnormality tracking continues, and the bag opening abnormality caused by unstable air supply or loose suction cup can be discovered in time, and a bag opening fault warning will be issued to remind the operator to deal with it in time.

[0004] To achieve the above object, the present invention provides the following technical solution: an automatic bag opening method. When the packaging machine switches from a stop or pause state to a start state, the automatic bag opening method matches the air source size with the current packaging bag. The matching rules are as follows:

[0005] (1) Collect the current packaging bag image data img0 and use the image matching method to match the packaging bag ID in the database;

[0006] (2) When the matching fails, the automatic bag opening method issues a data non-entry warning;

[0007] (3) When the match is successful, the automatic bag opening method extracts the gas source size p1 currently used by the packaging machine, and simultaneously extracts the gas source size p0 corresponding to the current ID in the database. When p1≠p0, the gas source parameters of the packaging machine are reset.

[0008] Specifically, the automatic bag opening method further includes a bag opening abnormality detection model. The detection types of the detection model at least include: normal, no bag, not opened, and bag opening dropped off. Among them, no bag, not opened, and bag opening dropped off belong to bag opening abnormalities. When a bag opening abnormality is detected, the automatic bag opening method issues a bag opening abnormality warning and records the abnormality type, and updates the bag opening abnormality count Re.

[0009] Specifically, the automatic bag opening method fits the gas source size equation as f(L, W, ty) according to the accumulated historical data, where f(L, W, ty) represents the gas source size, L represents the length of the packaging bag, W represents the width of the packaging bag, and ty represents the type of the bag opening suction cup used.

[0010] Further, when the image matching method fails to match the packaging bag, the automatic bag opening method also performs automatic adaptation of the gas source size to the packaging bag, including:

[0011] (a) Wait for a set time after the packaging machine starts;

[0012] (b) Combine the image processing method with the camera parameters to calculate the actual length L and width W of the packaging bag corresponding to the img0 image;

[0013] (c) Calculate the initial gas source size g0 according to the gas source size adaptation equation f(L, W, ty) and use g0 for bag opening. When the bag opening is normal for M consecutive times, set α = -1 and continue to judge the condition J = "the bag opening is normal for M consecutive times", otherwise set α = 1 and continue to judge the condition J = "there is an abnormality in M times of bag opening", where M is a preset value;

[0014] (d) Set the used gas source size , where Δg represents the preset adjusted gas source size step. When g1 < g_min or g1 > g_max, the automatic adaptation exits, and the automatic bag opening method reports a warning that the gas source size exceeds the threshold, where g_min and g_max are the preset minimum and maximum gas source thresholds;

[0015] (e) Use g1 for bag opening. When J meets the condition, reassign g0 = g1 and return to step d. When J does not meet the condition, exit the loop of steps d and e, and set the bag opening gas source size ;

[0016] (f) Create a new current packaging bag ID and save the packaging bag ID, the corresponding image img0, and the gas source size g to the database.

[0017] Preferably, during the normal operation stage of the packaging machine, the bag-opening abnormality detection model monitors in real time. When a bag-opening abnormality occurs, the automatic bag-opening method sets the bag-opening suction cup to open the bag n more times. When the bag-opening is normal during these n times, the packaging machine operates normally, and at the same time, the counter Rn for multiple bag-opening abnormalities increments by 1. When the bag-opening is abnormal all n times, the current packaging bag is discarded and a new bag is grabbed for operation. At the same time, the counter Rl for bag discarding increments by 1, where n is a preset value.

[0018] Specifically, when Rn + Rl of the counter for multiple bag-opening abnormalities > threshR, the automatic bag-opening method issues a bag-opening failure warning, where threshR is a preset abnormal count threshold.

[0019] Specifically, during the normal operation stage of the packaging machine, each time the packaging machine runs, the total packaging counter N increments by 1. When N < threshN, the counters Rn and Rl for multiple bag-opening abnormalities do not record, where threshN is a preset value.

[0020] Specifically, at every set time interval, the automatic bag-opening method integrates the newly added data in the database to update the bag-opening abnormality detection model and the air source size adaptation equation f(L, W, ty).

[0021] Specifically, the present invention also provides an automatic bag-opening system, including:

[0022] An image acquisition module that acquires the image data img0 of the packaging bag for packaging bag ID matching, bag-opening abnormality detection, and calculation of the packaging bag dimensions L and W;

[0023] A bag-opening detection module that runs the bag-opening abnormality detection model and outputs the detection result. The detection result includes at least: normal, no bag, not opened, bag-opening dropped off. Among them, no bag, not opened, and bag-opening dropped off belong to bag-opening abnormalities. When a bag-opening abnormality is detected, the data display module gives a bag-opening abnormality warning display. At the same time, the data storage module stores the current abnormality type and updates the abnormality count value;

[0024] An air source matching module that runs the automatic adaptation method of the air source size to the packaging bag;

[0025] A bag-opening processing module that completes the processing logic during the normal operation stage of the packaging machine;

[0026] A model update module that, at every set time interval, integrates the newly added data in the data storage module to update the bag-opening abnormality detection model and the air source size adaptation equation f(L, W, ty);

[0027] The data display module displays the working information of the packaging machine, which includes at least: the reminder of the matching of the gas source size with the current packaging bag, the result of the abnormal bag opening detection, the reminder of the automatic adaptation of the gas source size and the packaging bag, the abnormal alarm, the abnormal bag opening count Re, the multiple abnormal bag opening counter Rn, the packet loss counter Rl, and the total packaging counter N;

[0028] The data storage module stores the bag opening anomaly detection model, the air source size adaptation equation f(L, W, ty), the used packaging bag data, the suction cup type used by the packaging machine, the bag opening anomaly count Re, the multiple bag opening anomaly counter Rn, the packet loss counter Rl, and the total packaging counter N. The used packaging bag data at least includes the packaging bag matching image set, the packaging bag ID, and the air source size p0 corresponding to the ID.

[0029] Furthermore, the present invention also provides a storage medium, which is a computer-readable storage medium for computer-readable storage, wherein the storage medium stores one or more programs, and the one or more programs can be executed by one or more processors to automatically perform the steps of the bag opening method.

[0030] Compared with the prior art, the present invention has the following beneficial effects:

[0031] 1. The present invention can automatically match the gas source size of the packaging machine with the customer's packaging bag by matching the gas source size with the current packaging bag and automatically adapting the gas source size to the packaging bag when the packaging bag does not match, thereby preventing the problem of reduced packaging quality due to inappropriate gas source size.

[0032] 2. The present invention sets up a bag opening abnormality detection network. When a bag opening abnormality is detected during the normal operation of the packaging machine, the bag opening abnormality caused by accidental factors is prevented by performing multiple bag opening operations.

[0033] 3. The present invention applies a bag opening abnormality detection network during the operation of the packaging machine. When the number of times the bag is opened or the number of times the packaging bag is discarded exceeds a certain threshold, the system issues a bag opening failure warning to remind the operator to handle it in time to prevent problems such as unstable air supply, air supply pipe leakage, loose suction cup, etc. from further causing bag opening quality problems. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 This is a logical diagram of the method for matching the gas source size with the current packaging bag of the present invention.

[0035] Figure 2 This is a logical diagram of automatic adaptation of the gas source size and the packaging bag of the present invention.

[0036] Figure 3 This is a schematic diagram of the automatic bag opening system module of the present invention. DETAILED DESCRIPTION

[0037] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0038] like Figure 3 As shown, the functional modules of an automatic bag opening system of the present invention mainly include: an image acquisition module, a bag opening detection module, an air source matching module (operating in the initial stage when the packaging machine is restarted), a bag opening processing module (operating in the stable working stage of the packaging machine), a model updating module, a data display module and a data storage module, wherein the data display module can be integrated with the original display of the packaging machine, and the automatic bag opening system of the present invention displays the relevant information of bag opening by sending the corresponding data to the display of the packaging machine; the newly added data integrated by the model updating module can be the packaging bag data newly added by the packaging machine user himself, or the packaging bag data newly added by the packaging machine manufacturer from different users. By adding data, the model is updated to improve the judgment ability and generalization ability of the model.

[0039] During operation, the present invention divides the packaging machine into two stages: one is when the packaging machine is just turned on or switched from a pause state to a running state. During this stage, work such as changing packaging bags may be performed, so it is necessary to recheck whether the packaging bags have been replaced; the second is when the packaging machine is in normal operation. During this stage, parameters such as the size of the gas source of the packaging machine have been successfully matched. During this process, if the gas source is unstable (the gas supply is unstable or the gas supply pipe leaks, etc.) or the suction cup becomes loose, the packaging machine may not be able to open the bag normally, so it is necessary to detect and inform the staff to carry out maintenance.

[0040] Specifically, when the packaging machine is just starting to work, Figure 1 As shown, the automatic bag opening method of the present invention first collects img0 and uses an image matching method to match the packaging bag ID, wherein the image matching here is an image processing method, which can be performed using template matching, feature matching or deep learning methods. If the match is successful, it means that the packaging bag currently in use is a packaging bag whose relevant parameters have been entered into the system, and the air source size p0 corresponding to the current ID in the database is directly extracted and compared with the air source size parameter p1 currently used by the packaging machine. When p1≠p0, the packaging machine air source parameters are reset.

[0041] In practical applications, the packaging bags used by a manufacturer using a packaging machine are generally basically determined. During the debugging stage of the packaging machine, all packaging bag parameters will be input into the system. Subsequently, a small number of new packaging bags will be added. The automatic bag opening method of the present invention will automatically adapt to the size of the air source required to match the new packaging bag.

[0042] As a supplement to the above method, the currently matched ID can also be directly compared with the packaging bag ID currently used by the packaging machine to see if they are consistent (the parameters stored in the packaging machine correspond to the packaging bag ID one by one).

[0043] When the above process fails to match the packaging bag, it may be that the match is incorrect or the current packaging bag is a newly added type. At this time, the system will alarm and require manual confirmation. If it is a matching error (it should be noted that the database of the present invention stores a template set of a certain type of packaging bag, including template images of various angles and scales, and the probability of matching errors is low), the packaging bag type is directly selected manually and the subsequent air source adaptation process is skipped. Otherwise, the new packaging bag air source size is automatically adapted, such as Figure 2 As shown, the automatic adaptation of the present invention is based on the condition "opening the bag normally for M consecutive times" (M is preset, and M=5 in this embodiment). When the condition is met, it means that the current size of the gas source is sufficient to open the bag, but the gas volume may be too large, which may cause multiple packaging bags to be sucked at the same time when sucking the packaging bags. On the other hand, it will cause waste of resources. Therefore, it is necessary to try to reduce the size of the gas source until the condition "opening the bag normally for M consecutive times" cannot be met. When the debugging of reducing the gas source is cut off, the last set of values ​​that meet the conditions are taken; when the condition "opening the bag normally for M consecutive times" is not met, that is, there are abnormalities in the M bag openings, at this time, the gas source size is too small, and the gas source needs to be increased until the condition "opening the bag normally for M consecutive times" is just met. At this time, the gas source size value that just meets the condition is directly taken. It should be noted that there are two points to note in this process:

[0044] When the packaging machine is just started, the air source may be unstable. This is normal. At this time, you need to wait for a while before adapting. After the air source of the packaging machine is stable, you can do the adaptation work.

[0045] The Δg value of increasing or decreasing the gas source size during the adaptation process is an empirical value. It is necessary to consider both the rapid and stable adjustment process of the gas source size and the reasonable critical value corresponding to the final adapted gas source size when the conditions are met or not met during the adaptation process (Δg=0.01MPa in the present invention). As a supplement to this solution, the final adapted gas source size can be set with a margin to ensure stable bag opening of the packaging machine, that is, the final adapted gas source size value is the result of the A times (such as A=2) before the adaptation is terminated, that is,

[0046] .

[0047] It should be further noted that the air source size adaptation equation f(L, W, ty) is a function of the length L, width W of the packaging bag and the suction cup type ty. In this embodiment, considering that the types of suction cups are limited, the air source size adaptation equation establishes separate equations for different suction cup types. In practical applications, the required value of the air source size is essentially positively correlated with the mass of the packaging bag. Generally, for the packaging bags grasped by suction cups, their mass is positively correlated with the size of the packaging bag. Therefore, in the present invention, the initial value of the air source size is directly calculated based on the visible and easily measurable size of the packaging bag. For example, for a 30mm diameter corrugated suction cup, f = 1.64 * L * W.

[0048] During the normal operation stage of the packaging machine, the present invention considers the situation where the suction force of the suction cup decreases due to certain reasons, resulting in abnormal bag opening. At the same time, it also considers the elimination of accidental factors, such as the packaging bag not being cut off (the packaging bag itself has no opening and cannot be opened), a large amount of dust on a certain packaging bag, and the decrease in the suction force of the suction cup. The reasons for the decrease in the suction force of the suction cup generally include the decrease in the supply air pressure, the leakage of the supply air pipe, and the loosening of the suction cup. Accordingly, the present invention performs real-time detection of abnormal bag opening during the normal working stage. When an abnormal bag opening occurs, an alarm for abnormal bag opening of the packaging bag is issued, and the bag opening abnormal counter Re is immediately updated. However, a bag opening failure alarm is not immediately issued (the alarm level of the failure alarm is relatively high), mainly for two reasons:

[0049] The abnormal bag opening may be accidental. Therefore, the system will issue an instruction to open the bag n times again (such as n = 2). If the bag is opened normally during the n times, only the multiple bag opening counter Rn is incremented by 1 this time, and no bag opening failure alarm is issued. If the bag is not opened successfully during the n times, the current packaging bag is discarded and a new bag is grabbed for work this time, and the lost bag counter Rl is incremented by 1 to ensure the continuity of the operation of the packaging machine and prevent abnormal bag opening caused by the quality problem of the packaging bag itself rather than the problem of the packaging machine. However, when Rn + Rl > threshR (such as threshR = 10), at this time, the abnormal bag opening of the packaging machine is too frequent and problem checking is required. The system issues a high-level alarm - a bag opening failure alarm. In applications, it can be further set that the packaging machine stops working when the high-level alarm is triggered.

[0050] When the packaging machine starts to work, if the packaging bag is correctly matched and the air source size is also appropriate, the system does not enter the adaptation process and there is no waiting time for the air source of the packaging machine to stabilize. Therefore, the present invention compares the total count N of the packaging operation with a preset threshN (such as threshN = 10). When N < threshN and an abnormal bag opening occurs, no bag opening abnormal count is performed, that is, Rn and Rl are not incremented, and only the total counter N is incremented by 1.

[0051] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An automatic bag opening method, characterized in that: When the packaging machine switches from the stop or pause state to the start state, the automatic bag opening method matches the air source size with the current packaging bag. The matching rules are as follows: (1) Collect the current packaging bag image data img0 and use the image matching method to match the packaging bag ID in the database; (2) When the matching fails, the automatic bag opening method issues a data non-entry warning; (3) When the match is successful, the automatic bag opening method extracts the gas source size p1 currently used by the packaging machine, and simultaneously extracts the gas source size p0 corresponding to the current ID in the database. When p1≠p0, the gas source parameters of the packaging machine are reset; The automatic bag opening method fits the air source size equation as f(L, W, ty) based on the accumulated historical data, where f(L, W, ty) represents the air source size, L represents the length of the packaging bag, W represents the width of the packaging bag, and ty represents the type of the bag opening suction cup used; When the image matching method fails to match the packaging bag, the automatic bag opening method also automatically adapts the air source size to the packaging bag, including: (a) After the packaging machine starts, wait for the set time; (b) The image processing method is combined with the camera parameters to calculate the actual length L and width W of the packaging bag corresponding to the img0 image; (c) Calculate the initial gas source size g0 according to the gas source size adaptation equation f(L, W, ty) and use g0 to open the bag. When the bag opening is normal for M consecutive times, set α=-1 and continue to judge the condition J="M consecutive bag openings are normal", otherwise set α=1 and continue to judge the condition J="There are abnormalities in M ​​bag openings", where M is a preset value; (d) Set the size of the gas source: , where Δg represents the preset step size for adjusting the air source size. When g1 < g_min or g1 > g_max, it automatically adapts and exits. The automatic bag-opening method reports a warning that the air source size exceeds the threshold, where g_min and g_max are the preset minimum and maximum thresholds of the air source; (e) Use g1 to open the bag. When J meets the condition, reassign g0=g1 and return to step d. When J does not meet the condition, exit the cycle of steps d and e and set the size of the bag opening air source: ； (f) Create and save the current packaging bag ID, and save the image img0 corresponding to the ID and the gas source size g into the database.

2. The automatic bag opening method according to claim 1, characterized in that: The automatic bag opening method also includes a bag opening abnormality detection model, and the detection model detection types include at least: normal, no bag, unopened bag, and bag opening detachment, among which no bag, unopened bag, and bag opening detachment belong to bag opening abnormalities. When a bag opening abnormality is detected, the automatic bag opening method issues a bag opening abnormality warning and records the abnormality type and updates the bag opening abnormality count Re.

3. The automatic bag opening method according to claim 2, characterized in that: During the normal working stage of the packaging machine, the bag opening abnormality detection model monitors in real time. When a bag opening abnormality occurs, the automatic bag opening method sets the bag opening suction cup to open the bag n times again. When the bag opening is normal in n times, the packaging machine operates normally. At the same time, the multiple bag opening abnormality counter Rn counts up by 1. When n bag openings are abnormal, the current packaging bag is discarded and the bag is captured again to work. At the same time, the packet loss counter Rl counts up by 1, where n is a preset value.

4. The automatic bag opening method according to claim 3, characterized in that: When the multiple bag opening abnormality counter Rn+Rl>threshR, the automatic bag opening method issues a bag opening failure warning, wherein threshR is a preset abnormality counting threshold.

5. The automatic bag opening method according to claim 4, characterized in that: During the normal operation stage of the packaging machine, each time the packaging machine runs, the total packaging counter N is incremented by 1. When N < threshN, the multiple bag-opening abnormal counters Rn and Rl do not record, where threshN is a preset value.

6. The automatic bag opening method according to claim 5, characterized in that: At every set time interval, the automatic bag-opening method incorporates newly added data in the database to update the bag-opening abnormality detection model and the air source size adaptation equation f(L, W, ty).

7. An automatic bag opening system using the automatic bag opening method according to any one of claims 1 to 6, characterized in that: The system includes: An image acquisition module that acquires the image data img0 of the packaging bag for packaging bag ID matching, bag-opening abnormality detection, and calculation of the packaging bag dimensions L and W; A bag-opening detection module that runs the bag-opening abnormality detection model and outputs the detection results. The detection results at least include: normal, no bag, not opened, bag-opening detachment. Among them, no bag, not opened, and bag-opening detachment belong to bag-opening abnormalities. When a bag-opening abnormality is detected, the data display module performs a bag-opening abnormality warning display, and at the same time, the data storage module stores the current abnormality type and updates the abnormality count value; An air source matching module that runs the automatic adaptation method of the air source size to the packaging bag; A bag-opening processing module that completes the processing logic during the normal operation stage of the packaging machine; A model update module that, at every set time interval, incorporates the newly added data in the data storage module to update the bag-opening abnormality detection model and the air source size adaptation equation f(L, W, ty); A data display module that displays the working information of the packaging machine. The information at least includes: a reminder for matching the air source size with the current packaging bag, the bag-opening abnormality detection result, a reminder for automatically adapting the air source size to the packaging bag, an abnormality warning, the bag-opening abnormality count Re, the multiple bag-opening abnormal counter Rn, the packet loss counter Rl, and the total packaging counter N; A data storage module that stores the bag-opening abnormality detection model, the air source size adaptation equation f(L, W, ty), the used packaging bag data, the type of suction cup used by the packaging machine, the bag-opening abnormality count Re, the multiple bag-opening abnormal counter Rn, the packet loss counter Rl, and the total packaging counter N. Among them, the used packaging bag data at least includes the packaging bag matching image set, the packaging bag ID, and the air source size p0 corresponding to the ID.

8. A storage medium, the storage medium being a computer-readable storage medium, used for computer-readable storage, characterized in that: The storage medium stores one or more programs, and the one or more programs can be executed by one or more processors to implement the steps of the automatic bag-opening method according to any one of claims 1-6.

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