Automatic apple sorting and boxing system and method

Abstract

According to the automatic apple sorting and boxing system and method, accurate detection of the weight, the size, the color and the sweetness of apples is achieved through the multi-sensor fusion technology, the sorting logic is optimized in combination with a digital twin platform, and low-damage boxing and data binding are completed through a servo mechanical arm and the RFID technology. The system can significantly improve the sorting efficiency and precision, reduces the labor cost and fruit loss, and is suitable for large-scale fruit processing scenes.

Description

Technical Field

[0001] The present invention relates to the technical field of fruit sorting and packing, and in particular to an automatic apple sorting and packing system and method based on multi-sensor fusion and digital twin technology. Background Art

[0002] At present, apple sorting and packing mainly rely on manual operation, which has the following problems: low efficiency, the speed of manual sorting is limited by the proficiency of workers, and it is difficult to meet the needs of large-scale orders; insufficient sorting accuracy, worker fatigue can easily lead to misclassification and omission, and it is impossible to accurately detect the intrinsic quality of apples such as sweetness and color; high breakage rate, irregular actions such as throwing and squeezing during manual operation can easily cause surface damage to apples; lack of data management, traditional sorting lacks real-time recording and analysis of sorting data, and it is difficult to trace the sorting process. Based on this, the present invention proposes an automated sorting and packing system that integrates multi-sensors, digital twins and intelligent control technologies to solve the above technical problems. Summary of the invention

[0003] The automatic apple sorting and packing system of the present invention improves sorting efficiency and accuracy and reduces labor costs and fruit losses.

[0004] To achieve this object, the present invention adopts the following technical solutions:

[0005] An automatic apple sorting and packing system, characterized by comprising:

[0006] Data management module, used for order management, equipment virtual simulation and data storage;

[0007] The master control module is used to receive order information and generate global control instructions;

[0008] Automatic feeding module, used to adjust the feeding rate according to order requirements;

[0009] The sorting module obtains the physical parameter information of the apples and controls the apples to enter the corresponding sorting belt;

[0010] The storage module scans the RFID tag of the packaging box and writes the physical parameter information of the apples. The servo robot grabs the apples and puts them into the packaging box.

[0011] Optionally, the data management module includes: an industrial computer for processing order information, data storage and equipment virtual simulation; a digital twin platform for mapping the status of physical equipment and optimizing sorting strategies.

[0012] Optionally, the master control module includes: an electric energy meter for measuring the power consumption of the system; and a temperature and humidity sensor for monitoring the environmental parameters of the system.

[0013] Optionally, the automatic feeding module includes: a hopper equipped with a solenoid valve for dynamically adjusting the feeding rate; a transmission belt with a tapered design, the width of which gradually narrows from the entrance to the middle, so as to ensure that the apples are arranged in a single row and in an orderly manner.

[0014] Optionally, the sorting module includes: a load-bearing sensor for measuring the weight of apples; a visual sensor for detecting the size, color and surface defects of apples; and a near-infrared spectral sensor for detecting the sugar content and internal quality of apples.

[0015] Optionally, the storage module includes: a barcode scanner for reading an RFID tag on a packaging box and binding the physical parameters of the apple;

[0016] The RFID writing device is used to write the physical parameter information of the apple into the corresponding packaging box; the servo manipulator has a multi-degree-of-freedom design and controls the grasping force through the solenoid valve to grasp the apple and put it into the packaging box.

[0017] Another object of the present invention is to provide an automatic apple sorting and packing method to improve sorting efficiency and accuracy and reduce labor costs and fruit losses.

[0018] To achieve this object, the present invention adopts the following technical solutions:

[0019] An automatic apple sorting and packing method, characterized by comprising the following steps:

[0020] S1: Data management module issues order information;

[0021] S2: The master control module receives order information and parses it to generate global control instructions;

[0022] S3: The automatic feeding module opens the corresponding number of hoppers according to the control instructions and adjusts the feeding rate;

[0023] S4: Obtain the physical parameter information of the apples and control the apples to enter the corresponding sorting belt;

[0024] S5: The storage module scans the RFID tag of the packaging box and writes the physical parameter information of the apples. The servo robot packs the box according to the preset arrangement pattern and triggers automatic box change when it is full.

[0025] Optionally, when an order changes, the data management module simulates the sorting process through the digital twin platform and optimizes and adjusts sensor parameters and robot paths.

[0026] Optionally, the storage module records the batch number, sorting time and parameter information of the apples through RFID tags, and synchronizes them with the cloud database.

[0027] Beneficial effects of the present invention:

[0028] Multi-sensor fusion, integrated weight, appearance and internal quality parameters, to achieve multi-dimensional sorting of apples;

[0029] Digital twin integration, pre-debugging sorting logic through virtual simulation, shortening system deployment cycle;

[0030] Flexible sorting strategy: supports dynamic adjustment of sorting rules (such as setting sweetness threshold according to customer needs).

[0031] This system can significantly improve sorting efficiency and accuracy, reduce labor costs and fruit losses, and is suitable for large-scale fruit processing scenarios. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 A block diagram of an automatic apple sorting and packing system provided in one embodiment of the present application;

[0033] Figure 2 An equipment layout diagram of an automatic apple sorting and packing system provided in one embodiment of the present application;

[0034] Figure 3 A network configuration diagram of an automatic apple sorting and packing system provided in one embodiment of the present application;

[0035] Figure 4 A flowchart of a method for automatically sorting and packing apples provided in one embodiment of the present application. DETAILED DESCRIPTION

[0036] In order to make the technical problems solved by the present invention, the technical solutions adopted and the technical effects achieved clearer, the technical solutions of the embodiments of the present invention will be further described in detail below in conjunction with the accompanying drawings. 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 those skilled in the art without creative work are within the scope of protection of the present invention.

[0037] In the description of the present invention, unless otherwise clearly specified and limited, the terms "connected", "connected", and "fixed" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0038] Please refer to Figure 1-Figure 3 , shows an automatic apple sorting and packing system according to an embodiment of the present application.

[0039] The system includes:

[0040] Data management module 101 is built on industrial computers and supports order management, equipment virtual simulation and data storage. It uses digital twin technology to achieve virtual-real linkage of the system, map the status of physical equipment in real time, and optimize sorting strategies.

[0041] The master control module 102 integrates a programmable logic controller (PLC) and a touch screen, and generates global control instructions after receiving order information; preferably, the master control module 102 is equipped with an electric energy meter and a temperature and humidity sensor to monitor energy consumption and environmental parameters in real time.

[0042] The automatic feeding module 103 includes a plurality of solenoid valve-controlled hoppers, which dynamically adjust the feeding rate according to order requirements; the transmission belt adopts a tapered design (wide at the entrance and narrow in the middle) to ensure that the apples are arranged in a single row and in an orderly manner.

[0043] The sorting module 104 is equipped with a multi-sensor fusion unit, including: a load-bearing sensor for accurately measuring the weight of apples; a visual sensor for capturing the size, color and surface defects of apples; and a near-infrared spectrum sensor for detecting the sugar content and internal quality of apples. The sorting module 104 controls the solenoid valve according to the sorting rules (such as weight classification and sweetness threshold) to guide the apples to the corresponding sorting belt.

[0044] Storage module 105 manages packaging boxes based on RFID technology. The scanner reads the label and binds the physical parameters of the apple. The servo robot adopts a multi-degree-of-freedom design and controls the gripping force through a solenoid valve to avoid damage to the apple. It supports automatic box changing function and triggers the new box to be put in place when the packaging box is full.

[0045] like Figure 2 As shown, the system equipment includes a conveyor belt 203, one or more upper hoppers 201 are arranged at the entrance of the conveyor belt 203, and one or more sorting belts perpendicular to the conveyor belt are arranged on the conveyor belt. Packing boxes 205 are placed at the tail of the conveyor belt and the sorting belt. The sorting belt is equipped with a servo manipulator.

[0046] like Figure 3 As shown, the data management module includes one or more industrial computers. The computer, data management module, master control module, automatic feeding module, sorting module, and storage module form a network through an industrial switch. The Modbus-TCP protocol is supported to achieve high-speed communication and remote monitoring and analysis of sorting data.

[0047] The operation process of the automatic apple sorting and packing system is as follows: Apple pickers put the picked apples into the upper hopper. The data management module issues order information, which includes but is not limited to sorting level, packing quantity and quality requirements. The general control module parses the order and generates control instructions. The automatic feeding module opens the upper hopper according to the order dynamics, and the transmission belt adjusts the speed to match the sorting rhythm. The sorting module simultaneously collects weight, visual and spectral data, combines machine learning models for quality grading, controls the opening and closing of the solenoid valve, and ensures that the apples enter the corresponding sorting belt accurately. The storage module writes the apple parameters into the RFID tag, and the robot packs the apples according to the preset arrangement mode to reduce transportation collisions.

[0048] For example, workers pour apples into the upper hopper, and the data management module issues an order (for example: sorting 500 boxes, sugar content ≥12°Brix, weight 200-250g). The transmission belt runs at a speed of 0.5m / s. Through sensor detection, those that meet the standards enter the A-level sorting belt, and those that do not meet the standards enter the B-level sorting belt. The visual sensor finds that apples with damaged skin or bad fruits directly enter the packaging box at the end of the conveyor belt. The servo robot arranges apples in an array of 20 apples per box, and the RFID tag records batch number, sorting time, quality and other data. When the order is temporarily changed (such as adding color grading requirements), the system simulates the sorting process through the digital twin platform, optimizes sensor parameters and robot paths, and ensures that the sorting efficiency is not affected.

[0049] In addition, the present application also discloses a method for automatically sorting and packing apples.

[0050] Please refer to Figure 4 , showing a flow chart of a method for automatic sorting and packing of apples.

[0051] like Figure 4 As shown, the method includes:

[0052] S1: The data management center issues order information;

[0053] S2: The master control module receives order information and issues control instructions;

[0054] S3: The automatic feeding module opens the corresponding number of hoppers according to the control instructions, and the apples enter the conveyor belt;

[0055] S4: The sorting module obtains the physical parameter information of the apples and controls the apples to enter the corresponding sorting belt;

[0056] S5: The storage module scans the RFID tag of the packaging box and writes the physical parameter information of the apples. The servo robot grabs the apples and puts them into the packaging box.

[0057] In summary, the present invention uses multi-sensor fusion technology to achieve accurate detection of apple weight, size, color and sweetness, combines the digital twin platform to optimize sorting logic, and uses servo manipulators and RFID technology to complete low-damage packaging and data binding, which can significantly improve sorting efficiency and accuracy, reduce labor costs and fruit losses, and is suitable for large-scale fruit processing scenarios. .

[0058] The above description is only a preferred embodiment of the present application and an explanation of the technical principles used. Those skilled in the art should understand that the scope of the invention involved in the present application is not limited to the technical solution formed by a specific combination of the above technical features, but should also cover other technical solutions formed by any combination of the above technical features or their equivalent features without departing from the inventive concept. For example, the above features are replaced with the technical features with similar functions disclosed in this application (but not limited to) by each other.

Claims

1. An automatic apple sorting and packing system, characterized in that: include: Data management module, used for order management, equipment virtual simulation and data storage; The master control module is used to receive order information and generate global control instructions; Automatic feeding module, used to adjust the feeding rate according to order requirements; The sorting module obtains the physical parameter information of the apples and controls the apples to enter the corresponding sorting belt; The storage module scans the RFID tag of the packaging box and writes the physical parameter information of the apples. The servo robot grabs the apples and puts them into the packaging box.

2. The automatic apple sorting and packing system according to claim 1, wherein: The data management module includes: Industrial computers, used for processing order information, data storage and equipment virtual simulation; Digital twin platform to map physical equipment status and optimize sorting strategies.

3. The automatic apple sorting and packing system according to claim 1, wherein: The master control module includes: Energy meter, used to measure the system's electricity consumption; Temperature and humidity sensors are used to monitor the environmental parameters of the system.

4. The automatic apple sorting and packing system according to claim 1, wherein: The automatic feeding module includes: The upper hopper is equipped with a solenoid valve to dynamically adjust the feeding rate; The conveyor belt adopts a tapered design, with the width gradually narrowing from the entrance to the middle to ensure that the apples are arranged in a single row and in an orderly manner.

5. The automatic apple sorting and packing system according to claim 1, wherein: The sorting module includes: Load cell, used to measure the weight of apples; Vision sensors to detect the size, color and surface defects of apples; Near-infrared spectroscopy sensor is used to detect the sugar content and internal quality of apples.

6. The automatic apple sorting and packing system according to claim 1, wherein: The storage module includes: A barcode scanner to read the RFID tag on the packaging box; RFID writing device, used to write the physical parameter information of apples into the corresponding packaging box; The servo manipulator, with a multi-degree-of-freedom design, controls the gripping force through solenoid valves to grab apples and put them into packaging boxes.

7. An automatic apple sorting and packing method, characterized in that: The following steps are involved: S1: Data management module issues order information; S2: The master control module receives order information and parses it to generate global control instructions; S3: The automatic feeding module opens the corresponding number of hoppers according to the control instructions and adjusts the feeding rate; S4: Obtain the physical parameter information of the apples and control the apples to enter the corresponding sorting belt; S5: The storage module scans the RFID tag of the packaging box and writes the physical parameter information of the apples. The servo robot packs the box according to the preset arrangement pattern and triggers automatic box change when it is full.

8. The method according to claim 7, characterized in that When the order changes, the data management module simulates the sorting process through the digital twin platform and optimizes and adjusts the sensor parameters and robot path.

9. The method according to claim 7, characterized in that: The storage module records the batch number, sorting time and parameter information of apples through RFID tags and synchronizes them with the cloud database.

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