Powder material filling control system with multi-direction automatic butt joint function

Abstract

The invention discloses a powder material filling control system with a multi-direction automatic butt joint function, and relates to the related field of filling control, and the system is characterized in that a verification unit is used for starting a butt joint auxiliary unit to carry out multi-direction detection, and a plurality of positioning direction data are determined to carry out automatic positioning; an alignment positioning frame is generated to align a filling head to a to-be-filled container opening to conduct automatic butt joint of powder materials, a material filling instruction is generated to activate an anti-overflow control unit to conduct material filling monitoring, a filling monitoring data set is obtained to conduct filling dynamic adjustment, a filling strategy is formulated to conduct filling interaction on the to-be-filled container, and filling interaction is conducted on the to-be-filled container. And an obtained material filling result is synchronized to the remote centralized management and control terminal to carry out intelligent filling control on the powder material. The technical problems that traditional filling equipment mostly depends on material filling in the fixed direction, automatic and accurate butt joint of a container opening is lacked, and dynamic adjustment in the filling process cannot be achieved are solved, and the technical effect that automatic alignment of a filling head and the container opening is achieved through real-time monitoring and feedback adjustment is achieved.

Description

Technical Field

[0001] The present application relates to the field of filling control, and in particular to a powder material filling control system with multi-directional automatic docking. Background Art

[0002] Automatic filling of powder materials is a complex operation that requires high precision in industrial production. Most traditional powder filling systems use a fixed-direction filling method, which usually requires manual adjustment of the container position to ensure that the container mouth is aligned with the filling head. However, this method not only increases the difficulty of operation, but also during the filling process, due to the flow characteristics of the powder material and the positioning error of the equipment, powder leakage or uneven filling is prone to occur, affecting production efficiency and material utilization. The current filling equipment on the market mainly relies on simple sensor detection, lacks the ability to accurately locate the container mouth position at multiple angles and directions, and is difficult to meet the filling needs of containers of different types and sizes. In addition, in the absence of feedback mechanisms and dynamic adjustments, problems such as overflow or incomplete filling during the filling process often cannot be adjusted in a timely manner. Summary of the invention

[0003] The present application provides a powder material filling control system with multi-directional automatic docking to solve the technical problems that traditional filling equipment mostly relies on material filling in fixed directions or limited angles, lacks automatic and precise docking with the container mouth, and is unable to achieve dynamic adjustment of the filling process. The application achieves the technical effect of automatically aligning the filling head with the container mouth through real-time monitoring and feedback adjustment.

[0004] The present application provides a powder material filling control system with multi-directional automatic docking, including: a multi-directional detection module, the multi-directional detection module is used to start the docking auxiliary unit based on the verification unit to perform multi-directional detection, and determine multiple positioning direction data; an automatic positioning module, the automatic positioning module is used to automatically position according to the multiple positioning direction data, generate an alignment positioning frame, align the filling head with the opening of the container to be filled according to the alignment positioning frame to automatically dock the powder material, and generate a material filling instruction; a filling monitoring module, the filling monitoring module is used to activate the anti-overflow control unit based on the material filling instruction to perform material filling monitoring, and obtain a filling monitoring data set; a dynamic adjustment module, the dynamic adjustment module is used to perform dynamic filling adjustment according to the filling monitoring data set and formulate a filling strategy; a filling interaction module, the filling interaction module is used to execute the filling strategy to perform filling interaction on the container to be filled, obtain material filling results, and synchronize the material filling results to a remote centralized control terminal to perform intelligent filling control of powder materials.

[0005] In a possible implementation, the multi-directional detection module performs the following processing: constructing a preset filling point based on the layout position data of the filling head, starting the verification unit to determine whether the container to be filled has reached the preset filling point; if the container to be filled has reached the preset filling point, starting the matching auxiliary unit; scanning the container to be filled to determine the container mouth to be filled, performing a multi-directional analysis on the container mouth to be filled by the matching auxiliary unit to determine N image capture points, where N is a positive integer greater than 2; performing multi-angle acquisition of the container mouth to be filled based on the N image capture points to obtain a multi-directional captured image; positioning and integrating the multi-directional captured image according to the N image capture points to determine the multiple positioning direction data.

[0006] In a possible implementation, the multi-directional detection module performs the following processing: performing feature analysis according to the N image capture points based on the multi-directional captured images to determine multiple image capture features; performing three-dimensional coordinate calculation according to the multiple image capture features in combination with the N image capture points to determine the multi-directional captured three-dimensional coordinate points of the container mouth to be filled; confirming the positioning state of the container mouth to be filled based on the multi-directional captured three-dimensional coordinate points, verifying the positioning state of the container mouth to be filled through the verification unit, and generating a positioning verification feedback result; performing a self-check based on the positioning verification feedback result to determine the multiple positioning direction data.

[0007] In a possible implementation, the automatic positioning module performs the following processing: performing image processing on the multi-directional captured image according to the multi-directional captured three-dimensional coordinate points to obtain multiple image key feature points; locating the container mouth to be filled in combination with the positioning state of the container mouth to be filled according to the multiple image key feature points to generate three-dimensional positioning data; performing alignment calculation on the container mouth to be filled based on the three-dimensional positioning data to generate an alignment positioning frame; performing continuous state tracking on the container to be filled to generate filling container state information; according to the alignment positioning frame combined with the filling container state information, aligning the filling head with the container mouth to be filled to automatically dock the powder material and generate the material filling instruction.

[0008] In a possible implementation, the automatic positioning module performs the following processing: traversing the multi-directional captured three-dimensional coordinate points through the alignment and positioning frame to generate a positioning instruction; starting the filling head to move and align according to the alignment and positioning frame according to the positioning instruction to obtain the alignment coordinate points; performing error analysis on the container mouth to be filled according to the alignment coordinate points to generate an alignment error value, and correcting the alignment and positioning frame based on the alignment error value to obtain an alignment optimization positioning frame; setting a filling parameter set through the alignment optimization positioning frame in combination with the filling container status information, performing filling docking according to the filling parameter set, and generating the material filling instruction.

[0009] In a possible implementation, the automatic positioning module performs the following processing: performing multi-point position recognition on the mouth of the container to be filled based on the multiple image key feature points to determine edge feature points and center position feature points; performing positioning analysis according to the edge feature points combined with the positioning state of the mouth of the container to be filled to obtain a first positioning analysis result; performing positioning analysis according to the center position feature points combined with the positioning state of the mouth of the container to be filled to obtain a second positioning analysis result; performing three-dimensional mapping calculation based on the first positioning analysis result and the second positioning analysis result to generate the three-dimensional positioning data.

[0010] In a possible implementation, the automatic positioning module performs the following processing: constructing a three-dimensional space coordinate system, mapping the edge feature points to the three-dimensional space coordinate system based on the first positioning analysis result, and obtaining a plurality of edge three-dimensional coordinate points; mapping the center position feature points to the three-dimensional space coordinate system based on the second positioning analysis result, and obtaining a center position coordinate point; assigning weights to the plurality of edge three-dimensional coordinate points and the center position coordinate point, and obtaining a plurality of weight coefficients; performing coordinate fusion calculations based on the plurality of weight coefficients, and generating the three-dimensional positioning data.

[0011] In a possible implementation, the filling interaction module performs the following processing: data packaging based on multiple filling interaction results to obtain an interaction data packet; synchronizing the interaction data packet to the remote centralized control terminal for filling feedback to generate filling feedback response data; performing data mining based on the filling feedback response data to generate multiple data to be adjusted; optimizing the filling strategy according to the multiple data to be adjusted to generate a filling optimization strategy.

[0012] One or more technical solutions provided in this application have at least the following technical effects or advantages: The powder material filling control system with multi-directional automatic docking provided in the present application solves the technical problems that traditional filling equipment mostly relies on material filling in a fixed direction or a limited angle, lacks automatic and precise docking with the container mouth, and is unable to achieve dynamic adjustment of the filling process. It achieves the technical effect of automatically aligning the filling head with the container mouth through real-time monitoring and feedback adjustment. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] In order to more clearly illustrate the technical solution of the embodiment of the present invention, the accompanying drawings of the embodiment of the present invention will be briefly introduced below. A flow chart is used in the present application to illustrate the operations performed by the system according to the embodiment of the present application. It should be understood that the preceding or following operations are not necessarily performed accurately in order. On the contrary, various steps can be processed in reverse order or simultaneously as needed. At the same time, other operations can also be added to these processes, or one or more operations can be removed from these processes.

[0014] Figure 1 A schematic diagram of the structure of a powder material filling control system with multi-directional automatic docking provided in an embodiment of the present application; Figure 2 A schematic diagram of the automatic docking process of a powder material filling control system with multi-directional automatic docking provided in an embodiment of the present application.

[0015] Explanation of the reference numerals: multi-directional detection module 10 , automatic positioning module 20 , filling monitoring module 30 , dynamic adjustment module 40 , filling interaction module 50 . DETAILED DESCRIPTION

[0016] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below.

[0017] In order to make the purpose, technical solutions and advantages of the present application clearer, the present application will be further described in detail below in conjunction with the accompanying drawings. The described embodiments should not be regarded as limiting the present application. All other embodiments obtained by ordinary technicians in the field without making creative work are within the scope of protection of this application.

[0018] In the following description, reference is made to "some embodiments", which describe a subset of all possible embodiments, but it is understood that "some embodiments" may be the same subset or different subsets of all possible embodiments, and may be combined with each other without conflict, and the terms "first\second" involved are merely to distinguish similar objects and do not represent a specific ordering of objects. The terms "including" and "having" and any variations are intended to cover non-exclusive inclusions, for example, a process, system, product, or server that includes a series of steps or units is not necessarily limited to those steps or units that are clearly listed, but may include other steps or modules that are not clearly listed or inherent to these processes, systems, products, or devices. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those generally understood by technicians in the technical field of this application. The terms used herein are for the purpose of describing the embodiments of the present application only.

[0019] The present application embodiment provides a powder material filling control system with multi-directional automatic docking, such as Figure 1 As shown, the system comprises: A multi-directional detection module 10, wherein the multi-directional detection module 10 is used to start a counterpart auxiliary unit to perform multi-directional detection based on the verification unit to determine multiple positioning direction data; Furthermore, the multi-directional detection module 10 in the system provided in the embodiment of the application is also used for: A preset filling point is constructed based on the layout position data of the filling head, and the verification unit is started to determine whether the container to be filled has reached the preset filling point; if the container to be filled has reached the preset filling point, the matching auxiliary unit is started; the container to be filled is scanned to determine the container mouth to be filled, and the matching auxiliary unit performs multi-directional analysis on the container mouth to be filled to determine N image capture points, where N is a positive integer greater than 2; based on the N image capture points, multi-angle acquisition is performed on the container mouth to be filled to obtain a multi-directional captured image; Firstly, according to the layout position data of the filling head, the relative coordinate position of the filling head is analyzed, and the filling point suitable for the container to be filled is constructed, which means that the preset filling point of the container is generated by analyzing the position of the filling head, combined with the size and shape of the container to be filled, to ensure that the filling head can dock accurately when the container reaches the specified position, and then the verification unit is started. The position of the container to be filled is monitored by the verification unit, which means that the verification unit detects the position of the container to be filled in real time through the position sensor to determine whether it has reached the preset filling point. If the verification unit confirms that the container has reached the preset filling point, the system starts the docking auxiliary unit. For the subsequent docking preparation work, the docking auxiliary unit performs a multi-directional scan on the container to be filled to determine the position and contour of the mouth of the container to be filled. The scanning data identifies the center position and edge features of the container mouth to be filled to locate the container mouth to be filled, and further performs multi-directional analysis on the container mouth to be filled through the docking auxiliary unit, which means that the docking auxiliary unit reasonably sets N image capture points based on the position of the container mouth and according to the shape and position of the container, and determines N capture points, where N is a positive integer greater than 2, and can capture the image of the container mouth from at least three different angles A, B, and C to ensure sufficient image coverage angles. At the same time, the image sensor of the docking auxiliary unit collects images from N different capture points, and each capture point obtains an image. The obtained images display the characteristics of the container mouth from different directions, ensuring that the position and shape information of the container mouth are completely captured, and ensuring the precise docking of the filling head and the container mouth.

[0020] The multi-directional captured images are positioned and integrated according to the N image capturing points to determine the multiple positioning direction data.

[0021] Furthermore, the multi-directional detection module 10 in the system provided in the embodiment of the application is also used for: Based on the multi-directional captured images, feature analysis is performed according to the N image capture points to determine multiple image capture features; three-dimensional coordinate calculation is performed based on the multiple image capture features in combination with the N image capture points to determine the multi-directional captured three-dimensional coordinate points of the container mouth to be filled; based on the multi-directional captured three-dimensional coordinate points, the positioning state of the container mouth to be filled is confirmed, and the positioning state of the container mouth to be filled is verified by the verification unit to generate a positioning verification feedback result; based on the positioning verification feedback result, a self-inspection is performed to determine the multiple positioning direction data.

[0022] The key features of N images captured in multiple directions are identified by image analysis algorithms (such as edge detection, corner point detection, feature point extraction, etc.), and then the image capture features of each image capture point are determined based on the key features in each image. The features may include the edge, corner points and other unique shape features of the container mouth, and then the feature point coordinates of each image capture point are converted into spatial coordinates, and the three-dimensional coordinates of each image capture feature are calculated by triangulation method or stereo vision algorithm. According to the calculation results of the three-dimensional coordinates of N image capture points, the multi-directional captured three-dimensional coordinate points of the container mouth to be filled are obtained, and the multi-directional captured three-dimensional coordinate points represent the spatial position of the container mouth to be filled at different viewing angles, and the positioning state of the container mouth to be filled is confirmed based on the multi-directional captured three-dimensional coordinate points, which means integrating all multi-directional three-dimensional coordinate points to generate the position and angle information of the container mouth in three-dimensional space, and determining the accurate positioning state of the container mouth to be filled.

[0023] Furthermore, the verification unit is started to verify the positioning status of the container mouth to be filled in real time. The verification unit detects whether the position and angle of the container mouth in three-dimensional space match the preset position of the filling head based on the three-dimensional coordinate point data of the container mouth. According to the result of the positioning status verification, a positioning verification feedback result is generated. The positioning verification feedback result may include information such as whether the verification is passed, the error range and the angle offset. At the same time, a self-check is performed based on the positioning verification feedback result, which means analyzing the error information in the positioning verification feedback result to determine whether the position or angle of the container mouth needs to be fine-tuned. If the verification result shows that the container mouth is offset or the angle does not meet the standard, the position of the container is adjusted, and the verification is repeated to confirm the final positioning direction data of the container mouth to ensure that it meets the accuracy requirements of the filling head docking, thereby realizing accurate positioning and self-checking of the container mouth, making the filling process more efficient and stable, and significantly improving the automation and adaptability of the filling system. An automatic positioning module 20, the automatic positioning module 20 is used to automatically position according to the multiple positioning direction data, generate an alignment positioning frame, align the filling head with the opening of the container to be filled according to the alignment positioning frame to automatically dock the powder material, and generate a material filling instruction; Further, such as Figure 2 As shown, the automatic positioning module 20 in the system provided in the application embodiment is also used for: Performing image processing on the multi-directionally captured image according to the multi-directionally captured three-dimensional coordinate points to obtain a plurality of image key feature points; The previously calculated three-dimensional coordinate points of multi-directional capture are used as the basis for image processing. Image processing is then performed on the multi-directional captured images. A feature detection algorithm such as SIFT or ORB algorithm is used to extract multiple image key feature points. The multiple image key feature points include the edge, corners and center point of the container mouth, etc., providing detailed position information of the container mouth.

[0024] Positioning the container opening to be filled in combination with the positioning state of the container opening to be filled according to the multiple image key feature points to generate three-dimensional positioning data; Furthermore, the automatic positioning module 20 in the system provided in the application embodiment is also used for: Based on the multiple key feature points of the image, multi-point position recognition is performed on the mouth of the container to be filled to determine edge feature points and center position feature points; positioning analysis is performed according to the edge feature points combined with the positioning state of the mouth of the container to be filled to obtain a first positioning analysis result; positioning analysis is performed according to the center position feature points combined with the positioning state of the mouth of the container to be filled to obtain a second positioning analysis result; Performing multi-point position identification on the mouth of the container to be filled based on multiple image key feature points means traversing the mouth of the container to be filled according to multiple image key feature points to perform feature identification point by point, and classifying the identified feature points according to edge feature points and center position feature points to obtain edge feature points and center position feature points, wherein the edge feature points are the outline and shape of the mouth of the container to be filled, and the center position feature points are the center position information of the mouth of the container to be filled; performing positioning analysis according to the edge feature points combined with the positioning state of the mouth of the container to be filled means analyzing the distribution and angle of the edge feature points, calculating the specific position and edge outline of the mouth of the container to be filled, and recording them as the first positioning analysis result; performing positioning analysis according to the center position feature points combined with the positioning state of the mouth of the container to be filled means calculating the center position of the mouth of the container based on the position of the center position feature points and the current positioning state of the mouth of the container, and the center coordinates and direction of the mouth of the container can be confirmed through the center position analysis, and recorded as the second positioning analysis result, thereby realizing the accurate three-dimensional positioning of the mouth of the container, and providing high-precision positioning data support for subsequent filling operations.

[0025] A three-dimensional mapping calculation is performed based on the first positioning analysis result and the second positioning analysis result to generate the three-dimensional positioning data.

[0026] Furthermore, the automatic positioning module 20 in the system provided in the application embodiment is also used for: Constructing a three-dimensional space coordinate system, mapping the edge feature points to the three-dimensional space coordinate system based on the first positioning analysis result, and obtaining a plurality of edge three-dimensional coordinate points; Mapping the central position feature point to the three-dimensional space coordinate system based on the second positioning analysis result to obtain a central position coordinate point; The plurality of edge three-dimensional coordinate points and the center position coordinate point are weighted to obtain a plurality of weight coefficients, and coordinate fusion calculation is performed according to the plurality of weight coefficients to generate the three-dimensional positioning data.

[0027] First, a standard three-dimensional space coordinate system is established to accurately map the edge and center position feature points of the container mouth to be filled later. A reference point can be set as the origin of the coordinate system based on the filling head position or the container mouth reference point, and the directions of the three axes X, Y, and Z are clarified to standardize the three-dimensional coordinates of each feature point of the container mouth. At the same time, the edge feature points of the container mouth are obtained based on the first positioning analysis results, and each edge feature point is mapped to the three-dimensional space coordinate system to generate multiple edge three-dimensional coordinate points. The multiple edge three-dimensional coordinate points are used to characterize the specific position of the edge of the container mouth to be filled in space, and provide a contour reference for filling docking. Further, the center position feature points of the container mouth are obtained based on the second positioning analysis results, and the center position feature points are mapped to the three-dimensional space coordinate system to generate the three-dimensional coordinate points of the center position as the core position reference of the container mouth.

[0028] Different weight coefficients are further assigned according to the importance of edge feature points and center position feature points. The weight of the center position coordinate point can be set higher to reflect the core docking position of the container mouth, while the weight of the edge point can be set lower to assist docking accuracy. On this basis, the weight coefficient is automatically assigned according to the distance, position distribution and other factors of each edge three-dimensional coordinate point. The edge coordinate points close to the center point are assigned higher weights, and the points farther away from the edge area are assigned lower weights. Finally, a set of weight coefficients for fusion calculation is obtained, that is, multiple weight coefficients, and the weighted fusion of multiple edge three-dimensional coordinate points and center position coordinate points is performed using the assigned weight coefficients, which means that the weighted average of each point is calculated according to the weight of each coordinate point, and then the final three-dimensional positioning data is generated according to the result of the fusion calculation. The three-dimensional positioning data contains the overall spatial position and direction information of the container mouth, which is used to guide the precise alignment and automatic docking operation of the filling head, and improves the intelligence and adaptability of the filling process.

[0029] Performing an alignment calculation for the container opening to be filled based on the three-dimensional positioning data to generate an alignment positioning frame; Continuously track the status of the container to be filled and generate the status information of the filling container; Based on the generated three-dimensional positioning data, the alignment position of the container mouth to be filled in the filling system is calculated, and an alignment positioning frame is generated. The generation of the alignment positioning frame ensures the spatial consistency between the container mouth and the filling head position. The parameter setting of the alignment positioning frame includes the edge coordinates and angle of the container mouth and the relative position of the filling head, ensuring that the filling head can be accurately docked to the container mouth. At the same time, the state tracking module is started during the filling process to monitor the position, angle and state changes of the container in real time, and based on the image data and sensor feedback, the filling container state information is continuously generated. The filling container state information may include the real-time position, angle change and possible offset of the container mouth. The filling container state information provides a dynamic adjustment basis for subsequent automatic docking.

[0030] According to the alignment and positioning frame combined with the filling container status information, the filling head is aligned with the opening of the container to be filled to automatically dock the powder material, and the material filling instruction is generated.

[0031] Furthermore, the automatic positioning module 20 in the system provided in the application embodiment is also used for: The multi-directional captured three-dimensional coordinate points are traversed through the alignment and positioning frame to generate a positioning instruction; according to the positioning instruction, the filling head is started to move and align according to the alignment and positioning frame to obtain the alignment coordinate points; according to the alignment coordinate points, an error analysis is performed on the container mouth to be filled to generate an alignment error value, and the alignment and positioning frame is corrected based on the alignment error value to obtain an alignment optimization positioning frame; the filling parameter set is set through the alignment optimization positioning frame in combination with the filling container status information, and the filling docking is performed according to the filling parameter set to generate the material filling instruction.

[0032] First, based on the multi-directional capture of the three-dimensional coordinate points in the alignment and positioning frame, the specific position of each coordinate point in the positioning frame is confirmed. Then, based on the traversal results, the system generates a positioning instruction, which contains the moving path of the filling head and the direction information of the alignment frame, and guides the filling head to gradually align with the container mouth. The filling head is further started and gradually moves according to the generated positioning instruction to ensure that the filling head enters the specified area of ​​the alignment and positioning frame. At the same time, after the filling head reaches the specified position of the alignment and positioning frame, the alignment coordinate point of the filling head is confirmed. The alignment coordinate point is used to reflect the spatial position relationship between the filling head and the container mouth. Then, according to the alignment coordinate point, the error analysis of the container mouth to be filled is performed, which means that the alignment error value can be calculated by analyzing the deviation between the actual position of the filling head and the target alignment point. The alignment error value may include horizontal deviation, vertical deviation and angle deviation, thereby generating an alignment error value. In order to better match the actual position of the container mouth and reduce the alignment deviation, the coordinates and angles of the alignment positioning frame are adjusted according to the alignment error value to generate an alignment optimization positioning frame. The filling parameter set is set according to the alignment optimization positioning frame, including key parameters such as filling flow rate, filling angle, and filling pressure. The setting of the filling parameter set is intended to ensure the stability and filling accuracy of the filling process. According to the set filling parameter set, the filling docking process is started, and the filling head is accurately aligned with the container mouth to avoid material leakage or overflow. After the docking is completed, the system generates a material filling instruction, instructs the filling head to start the filling operation, and controls parameters such as flow rate and pressure during the filling process, which improves the automation level and stability of the filling system.

[0033] A filling monitoring module 30, the filling monitoring module 30 is used to activate the anti-overflow control unit to perform material filling monitoring based on the material filling instruction, and obtain a filling monitoring data set; The material filling instruction is sent to the filling head control module, and the start of the overflow prevention control unit is triggered at the same time. That is, after the material filling instruction is issued, the overflow prevention control unit is activated and enters the real-time monitoring state. The overflow prevention control unit includes a liquid level sensor, a flow rate sensor and a pressure sensor, etc., which can be used to monitor key parameters in the filling process. The overflow prevention control unit can set the overflow threshold of the filling container during the monitoring process. The set overflow threshold can include key control points such as the liquid level upper limit and the flow rate upper limit, to ensure that the filling rate can be automatically adjusted once the parameter is monitored to be close to the threshold.

[0034] Further material filling monitoring by the anti-overflow control unit may include liquid level monitoring, flow rate monitoring, pressure monitoring, etc. The liquid level monitoring refers to the liquid level sensor continuously monitoring the material level in the container, and recording the material filling height in real time to ensure that the liquid level does not exceed the preset upper limit. Flow rate monitoring refers to the flow rate sensor monitoring the material flow rate in real time to ensure that the flow rate of the material entering the container during the filling process is stable and does not exceed the flow rate threshold. Pressure monitoring refers to the pressure sensor monitoring the internal pressure of the filling head to prevent abnormal pressure during the filling process from causing material overflow or splashing. Finally, the monitoring data such as liquid level, flow rate, pressure, etc. are collected and recorded in real time to generate a filling monitoring data set to ensure the safety and efficiency of filling.

[0035] A dynamic adjustment module 40, the dynamic adjustment module 40 is used to perform dynamic adjustment of filling according to the filling monitoring data set and formulate a filling strategy; During the filling process, the filling monitoring data set is continuously acquired, including data such as liquid level, flow rate, pressure, etc., the filling status is analyzed in real time, and key data points such as liquid level approaching overflow, flow rate fluctuation, and pressure abnormality in the filling monitoring data set are extracted, and nodes that may need dynamic adjustment are identified. Trend analysis is performed based on the historical records and real-time status in the monitoring data set, and possible changes in the filling process are predicted. Trend analysis results are generated, and on this basis, it is determined whether dynamic filling adjustment is required. Exemplarily, when the liquid level approaches the preset overflow threshold or the flow rate fluctuates, the system will trigger the dynamic adjustment conditions. When the dynamic adjustment conditions are met, the filling parameters, including filling flow rate, filling head position, pressure control, etc., are automatically adjusted to ensure the stability and safety of the filling process. At the same time, after each parameter adjustment, the adjustment effect can be fed back in real time through the monitoring data set to ensure that the adjustment is in line with expectations and no new abnormal conditions are generated.

[0036] Furthermore, an appropriate filling speed control strategy is formulated based on the liquid level data and flow rate data. For example, when the liquid level approaches the upper limit of the container, the filling flow rate is gradually reduced to prevent overflow; if the liquid level is below the safe range, the filling speed is appropriately accelerated to improve the filling efficiency. A pressure control strategy can also be formulated based on the pressure sensor data. For example, if the pressure is too high, it may cause material splashing, and the risk will be avoided by reducing the filling pressure; if the pressure is low, the pressure will be appropriately increased to keep the filling smooth, and the container response strategy will be formulated in combination with the container's stable state information (such as angle change or displacement). For example, if a slight offset of the container is detected, the position angle of the filling head will be adjusted to ensure alignment and improve the accuracy of filling. At the same time, to prevent overflow during the filling process, the deceleration or suspension of filling instructions can be triggered in advance when the liquid level reaches the preset warning value, and filling can be continued after the container is stable to ensure the safety of the filling process. Finally, based on different filling parameters, a multi-level filling strategy is formulated to achieve a high-precision, automated filling process, effectively reduce filling errors, prevent material overflow, and ensure filling stability and efficiency.

[0037] The filling interaction module 50 is used to execute the filling strategy to perform filling interaction on the container to be filled, obtain the material filling result, and synchronize the material filling result to the remote centralized control terminal to perform intelligent filling control on the powder material.

[0038] According to the formulated filling strategy, the filling is started to execute the strategy parameters such as flow rate control, pressure regulation and position alignment to ensure the precise docking of the filling head and the container mouth. During the filling process, the system monitors the key parameters such as liquid level, flow rate and pressure in real time, and dynamically adjusts the filling strategy according to the actual situation. When the filling liquid level reaches the predetermined capacity or the filling process is detected to be close to completion, the filling speed is automatically reduced and gradually stopped. After the filling is completed, the final filling volume is recorded to ensure that the container reaches the preset material filling level. The filling quality of the material can be detected by weighing or sensor to ensure the accuracy of the filling volume. By comparing the detected filling volume with the preset standard, if the requirements are met, the filling is confirmed to be qualified, and if not, it is marked as abnormal, so as to determine the material filling result.

[0039] The material filling results (including filling volume, filling time, operating parameters and quality inspection results, etc.) are further organized into a unified format and synchronized to the remote control terminal. After receiving the filling results, the remote terminal updates the filling status and material filling information in real time to ensure that all data are archived and monitored in the centralized control system. Then, the remote centralized control terminal analyzes the relationship between filling effect and operating parameters based on the data of multiple filling tasks, and provides data support for subsequent filling processes. Through data analysis, the filling strategy is further optimized, including the setting of parameters such as flow rate adjustment, pressure control, and filling sequence, to improve the overall filling efficiency and accuracy of the system, providing important support for the development of intelligent filling systems.

[0040] Furthermore, the filling interaction module 50 in the system provided in the application embodiment is also used for: Data is packaged based on multiple filling interaction results to obtain an interactive data packet; the interactive data packet is synchronized to the remote centralized control terminal for filling feedback to generate filling feedback response data; data mining is performed based on the filling feedback response data to generate multiple data to be adjusted; the filling strategy is optimized according to the multiple data to be adjusted to generate a filling optimization strategy.

[0041] After multiple filling interactions are completed, the key data of each filling process (such as filling volume, flow rate, pressure, liquid level changes, abnormal conditions, etc.) are collected and sorted, and the multiple filling interaction results are packaged in a unified format to generate an interactive data packet. The data packet contains the operating parameters, monitoring data, quality inspection results, and abnormal alarm information for each filling. The generated interactive data packet is then transmitted to the remote centralized control terminal through the network. After the remote control terminal receives the interactive data packet, it quickly analyzes the information in the data packet, identifies common problems and improvement space in the filling process, and generates filling feedback response data. The feedback information is classified and sorted according to the parameters, abnormal conditions, and quality standards in the filling process to form a feedback data set that can be used to optimize the filling strategy. Data mining of the filling feedback response data refers to extracting regular problems and potential optimization points in the filling process through statistical analysis, cluster analysis, and other methods, obtaining data mining results, and performing adjustment analysis based on the data mining results. It can include excessive flow rate fluctuations, filling accuracy deviations, and common filling volumes. Insufficient or overflow situations, etc., thereby generating multiple data to be adjusted, and classifying the data to be adjusted according to priority, ensuring that important adjustment data can be used for optimization strategy first, and classifying different types of data to be adjusted, such as flow rate adjustment, pressure adjustment, etc., according to multiple data to be adjusted, various parameters such as flow rate, pressure, and upper limit of filling volume in the filling strategy are optimized and set, and the optimized parameters are combined into a new filling strategy to generate a filling optimization strategy. The filling optimization strategy is used to adapt to the actual needs of the filling system and improve the filling efficiency and quality, realizes intelligent filling control based on multiple filling results, has adaptive optimization capabilities, and improves the efficiency, stability and accuracy of the filling process.

[0042] The embodiments of the present application solve the technical problems that traditional filling equipment mostly relies on material filling in a fixed direction or a limited angle, lacks automatic and precise docking with the container mouth, and is unable to achieve dynamic adjustment of the filling process, and achieves the technical effect of automatically aligning the filling head with the container mouth through real-time monitoring and feedback adjustment.

[0043] The above specific implementation manner does not constitute a limitation to the protection scope of the present application. It should be understood by those skilled in the art that various modifications, combinations and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present application should be included in the protection scope of the present application. In some cases, the actions or steps recorded in the present application can be performed in an order different from that in the embodiment and can still achieve the desired results. In addition, the process depicted in the accompanying drawings does not necessarily require the specific order or continuous order shown to achieve the desired results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

Claims

1. It has a powder material filling control system with multi-directional automatic docking, characterized by: The system comprises: A multi-directional detection module, which is used to start the counterpart auxiliary unit to perform multi-directional detection based on the verification unit to determine multiple positioning direction data; An automatic positioning module, the automatic positioning module is used to automatically position according to the multiple positioning direction data, generate an alignment positioning frame, align the filling head with the opening of the container to be filled according to the alignment positioning frame to automatically dock the powder material, and generate a material filling instruction; A filling monitoring module, the filling monitoring module is used to activate the anti-overflow control unit to perform material filling monitoring based on the material filling instruction, and obtain a filling monitoring data set; A dynamic adjustment module, the dynamic adjustment module is used to perform dynamic adjustment of filling according to the filling monitoring data set and formulate a filling strategy; The filling interaction module is used to execute the filling strategy to perform filling interaction on the container to be filled, obtain the material filling result, and synchronize the material filling result to the remote centralized management and control terminal to perform intelligent filling control on the powder material.

2. The powder material filling control system with multi-directional automatic docking according to claim 1, characterized in that: The multi-directional detection module system includes: Constructing a preset filling point based on the layout position data of the filling head, and starting the verification unit to determine whether the container to be filled has reached the preset filling point; If the container to be filled reaches the preset filling point, the docking auxiliary unit is activated; Scan the container to be filled to determine the opening of the container to be filled, and perform multi-directional analysis on the opening of the container to be filled by the opening auxiliary unit to determine N image capture points, where N is a positive integer greater than 2; Based on the N image capture points, multi-angle capture is performed on the mouth of the container to be filled to obtain a multi-directional captured image; The multi-directional captured images are positioned and integrated according to the N image capturing points to determine the multiple positioning direction data.

3. The powder material filling control system with multi-directional automatic docking as claimed in claim 2, characterized in that: The multi-directional detection module system includes: Performing feature analysis according to the N image capture points based on the multi-directional captured images to determine a plurality of image capture features; Calculate the three-dimensional coordinates according to the multiple image capture features and the N image capture points to determine the multi-directional capture three-dimensional coordinate points of the container mouth to be filled; Confirming the positioning state of the mouth of the container to be filled based on the three-dimensional coordinate points captured in multiple directions, verifying the positioning state of the mouth of the container to be filled by the verification unit, and generating a positioning verification feedback result; Based on the positioning verification feedback result, a corresponding self-check is performed to determine the multiple positioning direction data.

4. The powder material filling control system with multi-directional automatic docking as claimed in claim 3, characterized in that: The automatic positioning module system includes: Performing image processing on the multi-directionally captured image according to the multi-directionally captured three-dimensional coordinate points to obtain a plurality of image key feature points; Positioning the container opening to be filled in combination with the positioning state of the container opening to be filled according to the multiple image key feature points to generate three-dimensional positioning data; Performing an alignment calculation for the container opening to be filled based on the three-dimensional positioning data to generate an alignment positioning frame; Continuously track the status of the container to be filled and generate the status information of the filling container; According to the alignment and positioning frame combined with the filling container status information, the filling head is aligned with the opening of the container to be filled to automatically dock the powder material, and the material filling instruction is generated.

5. The powder material filling control system with multi-directional automatic docking as claimed in claim 4, characterized in that: The automatic positioning module system includes: Traversing the three-dimensional coordinate points captured in multiple directions through the alignment positioning frame to generate positioning instructions; According to the positioning instruction, the filling head is started to move and align according to the alignment positioning frame to obtain the alignment coordinate point; Perform error analysis on the container mouth to be filled according to the alignment coordinate points to generate an alignment error value, and correct the alignment positioning frame based on the alignment error value to obtain an alignment optimization positioning frame; A filling parameter set is set by combining the alignment optimization positioning frame with the filling container status information, and filling docking is performed according to the filling parameter set to generate the material filling instruction.

6. The powder material filling control system with multi-directional automatic docking according to claim 4, characterized in that: The automatic positioning module system includes: Based on the multiple key feature points of the image, multi-point recognition is performed on the mouth of the container to be filled to determine edge feature points and center position feature points; Performing positioning analysis according to the edge feature points in combination with the positioning state of the container mouth to be filled, to obtain a first positioning analysis result; Performing positioning analysis according to the central position feature point in combination with the positioning state of the container mouth to be filled, to obtain a second positioning analysis result; A three-dimensional mapping calculation is performed based on the first positioning analysis result and the second positioning analysis result to generate the three-dimensional positioning data.

7. The powder material filling control system with multi-directional automatic docking according to claim 6, characterized in that: The automatic positioning module system includes: Constructing a three-dimensional space coordinate system, mapping the edge feature points to the three-dimensional space coordinate system based on the first positioning analysis result, and obtaining a plurality of edge three-dimensional coordinate points; Mapping the central position feature point to the three-dimensional space coordinate system based on the second positioning analysis result to obtain a central position coordinate point; The plurality of edge three-dimensional coordinate points and the center position coordinate point are weighted to obtain a plurality of weight coefficients, and coordinate fusion calculation is performed according to the plurality of weight coefficients to generate the three-dimensional positioning data.

8. The powder material filling control system with multi-directional automatic docking according to claim 1, characterized in that: The filling interaction module system includes: Packing data based on multiple filling interaction results to obtain interaction data packets; Synchronize the interactive data packet to the remote centralized control terminal for filling feedback, and generate filling feedback response data; Performing data mining according to the filling feedback response data to generate a plurality of data to be adjusted; The filling strategy is optimized according to the plurality of data to be adjusted to generate a filling optimization strategy.

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