Eight-channel grain counting machine system

Abstract

The invention relates to an eight-channel grain counting machine system. The eight-channel grain counting machine system comprises a main control chip module, a control and analog signal output module and a signal output module, the signal input module is in communication connection with the main control chip module; the signal output module is in communication connection with the main control chip module; the analog signal output module is used for generating stable analog voltage through a PWM conversion circuit so as to control an external actuator; the relay control module is in communication connection with the main control chip module; the power supply module is used for supplying power to each module; the communication circuit module is divided into a grating plate communication circuit and an upper computer communication circuit and is used for detecting counting of medicine granules or particulate matters, and the upper computer communication circuit is communicated with an upper computer touch screen; and a storage module. According to the scheme, through multi-module cooperative control, an efficient communication architecture and dynamic coordination logic, eight-channel independent counting and control are supported, the sub-packaging efficiency is improved by 8 times compared with that of traditional single-channel equipment, and the system is suitable for large-scale production requirements and suitable for high-precision sub-packaging scenes of pharmacy, food particles and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of granule counting machines, and specifically to an eight-channel granule counting machine system and its pipeline control method. Background Art

[0002] Currently, there are various packaging machines popular in the market, which are usually packaging machines specifically set for specific products. The fully automatic granule counting machine uses the principle of photoelectric effect to input the working signal generated by the infrared dynamic scanning sensor when the medicine granules fall into the FPGA high-speed microprocessor, and realizes the counting function through the cooperation of circuits and programs.

[0003] Traditional granule counting machines have the following deficiencies: they only support single-channel counting, cannot meet the requirements of multi-station parallel sub-packaging, are relatively low in efficiency, lack linkage logic for actuators such as vibrators, solenoid valves, and conveyor belts, are prone to cause medicine granule blockage or overflow, and have insufficient coordinated control. Summary of the Invention

[0004] The present invention proposes an eight-channel granule counting machine system that realizes high-precision counting and sub-packaging of multi-channel medicine granules / particles through the coordinated communication and control logic between the main control board, grating board, solenoid valve board, vibrator, and upper computer, and solves the above problems existing in the prior art during use.

[0005] The technical solution of the present invention is realized as follows: An eight-channel granule counting machine system, characterized in that: A main control chip module, used to detect input signals, generate control instructions after collecting the signals, and control the analog signal output module and the signal output module; A signal input module, communicatively connected to the main control chip module, forms an input signal instruction through detection; a signal instruction fed back to the main control chip module; A signal output module, communicatively connected to the main control chip module. If it is necessary to control an external solenoid valve, the main control chip module controls to send an instruction to the signal output module to open or close the solenoid valve; An analog signal output module, generates a stable analog voltage through a PWM conversion circuit to control an external actuator; A relay control module, communicatively connected to the main control chip module, and this relay control module controls the operation of the conveyor belt; A power supply module, used to supply power to each module; A communication circuit module, divided into a grating board communication circuit and an upper computer communication circuit. The grating board communication circuit communicates with the grating board module. After the grating board module receives the signal, it starts to work to detect the counting of medicine granules or particles. The upper computer communication circuit communicates with the upper computer touch screen; A storage module, used for parameter preservation; Among them, the PWM conversion circuit includes a MOS tube circuit for processing the stability of the square wave signal, a voltage stabilization circuit connected to the MOS tube circuit and for processing voltage stability, a two-stage RC filtering circuit for converting the square wave signal into a DC signal, and a voltage follower for generating an analog voltage signal to control the vibrator after processing.

[0006] Preferably, the MOS tube circuit of the PWM conversion circuit includes a first MOS tube, a second MOS tube, a resistor R17, and a resistor R29. The first MOS tube is connected to the resistor R17, and the second MOS tube is connected to the resistor R29. The first MOS tube and the second MOS tube are in parallel. The voltage stabilization circuit includes a precision voltage stabilizing tube for voltage stabilization. The two-stage RC filtering circuit includes a first RC filtering circuit and a second RC filtering circuit connected in series. The first RC filtering circuit is connected to the precision voltage stabilizing tube, and the second RC filtering circuit is connected to the voltage follower.

[0007] Preferably, it further includes a voltage anti-interference module for providing a precision voltage for the analog circuit and a reference voltage module. The reference voltage module is connected to the main control chip module to generate a reference voltage for giving the voltage required for adjustment by the analog signal output module.

[0008] Preferably, the signal input module includes a first detection unit for detecting whether there is a bottle on the pipeline, a second detection unit for detecting whether the bottle is blocked, an emergency stop signal input unit, and a spare detection unit.

[0009] Preferably, the first detection unit includes a sensor, a high and low circuit module for judging the high and low of the sensor signal input, a signal isolation module, and a signal indicator light for visually displaying high level or low level. The sensor is used as the input signal end. The high and low circuit is disconnected from the input signal of the sensor and processed through the signal isolation module to achieve signal anti-interference.

[0010] Preferably, the signal output module includes a signal output terminal MOS tube for receiving instructions from the main control chip, a MOS tube working state indicator light, and a solenoid valve control chip for receiving instructions from the signal output terminal MOS tube.

[0011] Preferably, the grating plate module communication includes a grating plate main control chip, a photoelectric signal transmitting end, and a photoelectric signal receiving end.

[0012] A pipeline control method for an eight-channel granule counting machine system includes the following steps: a) After receiving the start instruction from the host computer, synchronously activate the conveyor belt, the vibration table, and the grating sensor; b) Real-time collect the material falling signal through the grating counting board, and the main control chip performs cumulative counting; c) When the count reaches the preset threshold, generate a solenoid valve control signal and a vibration table adjustment signal; d) Upload the device status to the touch screen interface in real time through the communication module; e) When receiving the emergency stop signal, cut off the power supply of all actuators and activate the status indicator light for alarm.

[0013] An eight-channel tablet counting machine system disclosed by the present invention, through multi-module collaborative control, an efficient communication architecture and a dynamic coordination logic, supports eight-channel independent counting and control. The packaging efficiency is increased by 8 times compared with traditional single-channel devices, which is suitable for large-scale production requirements and high-precision packaging scenarios such as pharmaceuticals and food granules. Each channel dynamically coordinates (the vibrator, solenoid valve, and conveyor belt are linked) to avoid the accumulation of medicine grains or the interruption of packaging, and realizes continuous operation. Brief Description of the Drawings

[0014] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can also be obtained based on these drawings without creative efforts.

[0015] Figure 1 It is a schematic diagram of the main control chip module of the present invention; Figure 2 It is a wiring circuit structure diagram of the first detection unit of the present invention; Figure 3 It is a wiring circuit structure diagram of the second detection unit of the present invention; Figure 4 It is a wiring circuit structure diagram of the emergency stop signal input unit of the present invention; Figure 5 Wiring circuit structure diagram of the standby detection unit; Figure 6 It is a schematic diagram of solenoid valve 1 of the signal output module; Figure 7 It is a schematic diagram of solenoid valve 2 of the signal output module; Figure 8 It is a schematic diagram of solenoid valve 3 of the signal output module; Figure 9 It is a schematic diagram of solenoid valve 4 of the signal output module; Figure 10 It is a schematic diagram of solenoid valve 5 of the signal output module; Figure 11 It is a wiring design diagram of the grating board communication circuit; Figure 12 It is a wiring design diagram of the host computer communication circuit; Figure 13 It is a wiring design diagram of the power supply module; Figure 14Wiring design diagram of the analog signal output module; Figure 15 Circuit connection diagram of the voltage anti-interference module; Figure 16 Circuit connection diagram of the reference voltage module; Figure 17 Circuit connection diagram of the storage module; Figure 18 Frame diagram of an eight-channel grain counting machine system. Specific implementation manner

[0016] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying Figure 1-18 drawings. Apparently, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention. Embodiment

[0017] As Figures 1 to 18 shown, this embodiment discloses an eight-channel grain counting machine system, Power supply module, used for power supply of each module; Refer to Figure 13 , the input is 24 volts. Through the designed protection circuit, and then through a DC-DC power supply module, a 5-volt voltage is generated, and the 5 volts is supplied to all circuits.

[0018] Main control chip module, refer to Figure 1 , which is a wiring distribution diagram, used to detect input signals, generate control instructions after collecting signals, and control the analog signal output module and the signal output module; A single-chip microcomputer is used.

[0019] Signal input module, refer to Figures 2-5 , is communicatively connected to the main control chip module to form an input signal instruction through detection; A signal instruction fed back to the main control chip module; Specifically, the signal input module includes a first detection unit for detecting whether there is a bottle on the detection pipeline, a second detection unit for detecting whether the bottle is blocked, an emergency stop signal input unit, and a spare detection unit.

[0020] The circuit designs of the first detection unit, the second detection unit, the emergency stop signal input unit, and the spare detection unit are exactly the same. The first detection unit is Figure 2 the wiring circuit structure diagram of; The second detection unit is Figure 3 the wiring circuit structure diagram of; The emergency stop signal input unit is Figure 4 the wiring circuit structure diagram of, and the spare detection unit is Figure 5 the wiring circuit structure diagram of.

[0021] Specifically, the first detection unit includes a sensor, a high-low circuit module for determining the high or low input of the sensor signal, a signal isolation module, and a signal indicator LED3 for visually displaying whether it is a high level or a low level; The 3rd pin of the sensor enters the 24V power supply module, and the sensor signal is connected to the high-low circuit module through the 2nd pin. The high-low circuit module includes a resistor R1, a capacitor C1, and a resistor R7. The capacitor C1 and the resistor R7 are in parallel. One end of the resistor R1 is connected to the 2nd pin of the sensor, and the other end of the resistor R1 is connected to one side of the capacitor C1; the signal isolation module includes an optocoupler PQ1817 for signal isolation, aiming to anti-interference. After signal isolation, the sensor signal is sent, and the signal indicator LED3 is connected after the optocoupler for visually displaying whether it is a high level or a low level signal. The sensor is used as the input signal terminal. The high-low circuit is connected to the input signal of the sensor and is processed by the signal isolation module to achieve signal anti-interference.

[0022] Signal output module, refer to Figures 6-10 , and is communicatively connected to the main control chip module. If it is necessary to control an external solenoid valve, the main control chip module controls and issues an instruction to the signal output module to determine whether to open or close the solenoid valve; The signal output module includes a signal output terminal mos tube Q1 for receiving instructions from the main control chip, a mos tube working status indicator LED1, and a solenoid valve control chip CN1 for receiving instructions from the signal output terminal mos tube. When the mos tube working status indicator LED1 drives the solenoid valve control chip CN to attract, the light is on, representing the attracted state. It should be noted that there are also multiple solenoid valves.

[0023] Analog signal output module, refer to Figure 14 , generates a stable analog voltage through a PWM conversion circuit to control an external actuator; eight are set with the same structure; The PWM conversion circuit includes a mos tube circuit for processing the stability of the square wave signal, a voltage stabilizing circuit connected to the mos tube circuit and for processing voltage stability, a two-stage RC filter circuit for converting the square wave signal into a DC signal, and a voltage follower U4A for generating an analog voltage signal to control the vibrator CN2 after processing.

[0024] The MOS transistor circuit of the PWM conversion circuit includes a first MOS transistor Q2, a second MOS transistor Q6, a resistor R17, and a resistor R29. The first MOS transistor is connected to the resistor R17, and the second MOS transistor is connected to the resistor R29. The first MOS transistor and the second MOS transistor are connected in parallel. The voltage stabilizing circuit includes a precision voltage stabilizing diode U5 for voltage stabilization, a resistor R20, a resistor R28, and a resistor R30. The resistor R20, the resistor R28, and the resistor R30 are connected in series in sequence. The MOS transistor circuit is connected between the resistor R20 and the resistor R28. The precision voltage stabilizing diode U5 is connected to the RC filtering circuit.

[0025] The two-stage RC filtering circuit includes a first RC filtering circuit and a second RC filtering circuit connected in series. The first RC filtering circuit is connected to the precision voltage stabilizing diode, and the second RC filtering circuit is connected to the voltage follower.

[0026] The first RC filtering circuit includes a resistor R25 and a capacitor C35, and the second RC filtering circuit includes a resistor R27 and a capacitor C36.

[0027] The characteristic of the analog signal output module in this solution is that it converts the square wave signal into an analog DC signal.

[0028] It also includes a voltage anti-interference module and a reference voltage module that provide precise voltage for the analog signal output module. The reference voltage module is connected to the main control chip module to generate a reference voltage, which is used to give the voltage required for adjustment of the analog signal output module and control the vibration amplitude of the vibrator.

[0029] The voltage anti-interference module refers to Figure 15 the circuit connection, and the reference voltage module refers to Figure 16 the circuit connection.

[0030] The relay control module is communicatively connected to the main control chip module, and the relay control module controls the operation of the conveyor belt; The communication circuit module is divided into a grating plate communication circuit and a host computer communication circuit. The grating plate communication circuit communicates with the grating plate module. After receiving the signal, the grating plate module starts to work for detecting the counting of medicine grains or particulate matters. The host computer communication circuit communicates with the host computer touch screen; The grating plate communication circuit includes a grating plate communication chip connected to the main control chip module and a protection circuit; The host computer communication circuit includes a host computer communication chip connected to the main control chip module and a protection circuit; The grating plate communication circuit refers to Figure 11 the wiring design diagram, and the host computer communication circuit refers to Figure 12 the wiring design diagram; The storage module is used for parameter saving; refer to Figure 17 the wiring design diagram.

[0031] The communication of the grating plate module includes a main control chip of the grating plate, a photoelectric signal transmitting end, and a receiving end for receiving photoelectric signals.

[0032] The working principle of the present invention is as follows: The main structure of the present invention: The main control board: The core control unit is responsible for signal processing, logical judgment, and communication scheduling. The grating plate (8 channels): Detects the falling of medicine grains / particles and generates counting pulse signals. The solenoid valve board: Controls the start and stop of medicine bottle dispensing (by the suction / release of solenoid valves). The vibrator (8 channels): Drives the medicine grains to fall orderly into the detection area. The conveyor belt: Transports the medicine bottles to the designated workstations. The sensors: Include position sensors (detecting the arrival of medicine bottles), vibrator status sensors, emergency stop sensors, etc. The touch screen (host computer): Parameter setting, status display, and manual operation interface.

[0033] After the button on the host computer is pressed, for example, to start, after the main control chip module receives this signal, it feeds back the opening signal to the relay control module, then starts the conveyor belt of the assembly line, and at the same time sends this signal to the grating plate, and forwards it to the grating plate module through the grating plate communication circuit, so that the grating plate module also starts to work. The grating plate is used to detect the falling of medicine grains or particles for counting, and all the counting signals are collected. When starting, at the same time, the control solenoid valve of the signal output module outputs, and at the same time, it is necessary to detect whether the sensor signals are ready, and at the same time start the vibrator. All things are started properly.

[0034] Only then will the medicine grains really fall down. When the medicine grains fall down and are detected by the grating plate, a counting signal is generated after detection. Then the main control remembers this counting signal. For example, when a bottle is full, it controls the vibrator or the solenoid valve to suck or temporarily stop.

[0035] For example, after a bottle is full, the main control board generates a signal to the grating plate, and the grating plate controls the solenoid valve signal to release; Basically, each part needs to work. If the host computer presses the stop button, it means stopping the conveyor belt, the vibrator, and the solenoid valve signal outside on the main control board.

[0036] The indicator lights among them also need to be controlled to generate different states.

[0037] Communication method: The solenoid valve and the main control chip are connected by a flat cable, which is directly connected by a wire. The grating plate and the main control board are connected through communication transmission, RS485 / CAN bus, to transmit counting signals and control instructions. The main control board and the touch screen of the upper computer are also connected through communication transmission. The optoelectronic signals collected by the grating plate and the control status of the solenoid valve need to be transmitted back to the main control board. After the main control board integrates these signals, on the one hand, it needs to control and process itself, and on the other hand, it also needs to transmit this information to the upper computer touch screen. There are many parameters and buttons on the upper computer touch screen. If the personnel perform operations, then the corresponding operation information needs to be transmitted to the main control board to make the main control board execute the corresponding operations. Communication architecture A pipeline control method for an eight-channel tablet counting machine system includes the following steps: a) After receiving the start instruction from the upper computer, synchronously activate the conveyor belt, vibration table and grating sensor; b) Real-time collect the material falling signal through the grating counting board, and the main control chip performs cumulative counting; c) When the count reaches the preset threshold, generate a solenoid valve control signal and a vibration table adjustment signal; d) Real-time upload the device status to the touch screen interface through the communication module; e) When receiving the emergency stop signal, cut off the power supply of all actuators and activate the status indicator light for alarm.

[0038] II. Control process 1. Start process Initialization detection Self-check of the main control board (status of communication, sensor, output module).

[0039] Detect whether each channel vibrator, grating plate, and solenoid valve are ready.

[0040] The touch screen displays the initialization status (green normal / red alarm).

[0041] Start operation The operator clicks the "Start" button on the touch screen, and the signal is sent to the main control board through communication.

[0042] The main control board executes in sequence: Start the conveyor belt → vibrator (soft start to prevent impact) → solenoid valve in the default closed state.

[0043] Send an instruction to the grating plate to start detection and enter the counting mode.

[0044] 2. Running stage (8 channels in parallel) Tablet counting and control ‌Raster plate‌: Real-time detection of the falling of medicine grains, independent counting for each channel, and sending a full-bottle signal to the main control board after reaching the preset value (such as N grains / bottle).

[0045] ‌Main control board‌: After receiving the full-bottle signal, control the solenoid valve of the corresponding channel to close (stop feeding).

[0046] Trigger the vibrator to pause (prevent overflow), and restart the vibration after a delay (ensure continuous feeding for the next bottle).

[0047] Update the touch screen count display and channel status (such as "Channel 1: Completed").

[0048] ‌Synchronization and coordination‌ The main control board monitors the conveyor belt position sensor to ensure accurate positioning of the medicine bottle below each channel.

[0049] If there is no signal continuously in a certain channel raster plate (clogging alarm), the main control board pauses the channel and triggers the vibrator to vibrate in the reverse direction to clear the blockage.

[0050] ‌3. Stop / Emergency stop process‌ ‌Normal stop‌ The operator clicks the "Stop" button on the touch screen. After the main control board receives the instruction: Turn off all vibrators, conveyor belts, and solenoid valves.

[0051] Reset the raster plate count data and save the current state to the memory.

[0052] The touch screen displays the "Standby" state, and the indicator light switches to yellow.

[0053] ‌Emergency stop handling‌ The emergency stop button triggers a hard-wired signal, and the main control board immediately cuts off all output power supplies (with a higher priority than communication instructions).

[0054] The alarm indicator light flashes, and a fault prompt interface pops up on the touch screen.

[0055] The upper computer touch screen provides the following functions: Set the target number of grains per channel, vibrator frequency, and communication timeout threshold; Real-time display of the counting progress, solenoid valve status, and alarm log of each channel; Support the single-channel manual debugging mode to forcibly start and stop the vibrator or solenoid valve.

[0056] ‌System startup phase‌: After the main control board receives the startup instruction from the upper computer, it starts the conveyor belt, vibrators of each channel, and the solenoid valves in the default closed state in sequence; Send a detection start instruction to the grating board through the RS485 / CAN bus to activate the pill counting function of the grating board.

[0057] Operation control stage: The grating board detects the falling of pills in real time and generates a counting signal, which is transmitted back to the main control board through communication; The main control board judges whether a single bottle of pills is full according to the preset threshold. If the threshold is reached, it controls the solenoid valve of the corresponding channel to close and suspends the vibrator; The main control board synchronously monitors the conveyor belt position sensor to ensure that the medicine bottles are accurately positioned below each channel.

[0058] Stop / Emergency stop stage: After receiving the stop instruction from the upper computer, the main control board turns off all vibrators, conveyor belts and solenoid valves, and resets the counting data of the grating board; When the emergency stop signal is triggered, the main control board immediately cuts off the power supply of the actuator and triggers an audible and visual alarm.

[0059] This solution Figure 1-17 Gives the specific wiring diagram and the parameters of the components. For example, R7 uses 15K, the resistor C1 uses 102C1 uses 102, etc., which can be referred to as a way of an embodiment.

[0060] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. An eight-channel pellet counting system, characterized in that: The main control chip module is used to detect input signals, collect signals, and generate control instructions to control the analog signal output module and the signal output module; The signal input module is connected to the main control chip module for communication, and forms an input signal instruction through detection; and feeds back the signal instruction to the main control chip module; The signal output module is connected to the main control chip module for communication. If an external solenoid valve needs to be controlled, the main control chip module will send instructions to the signal output module to determine whether to open or close the solenoid valve. Analog signal output module, which generates stable analog voltage through PWM conversion circuit to control external actuator; A relay control module is connected to the main control chip module for controlling the operation of the conveyor belt; Power module, used to supply power to each module; The communication circuit module is divided into a grating plate communication circuit and a host computer communication circuit. The grating plate communication circuit communicates with the grating plate module. The grating plate module starts working after receiving the signal to detect the counting of medicine particles or particulate matter. The host computer communication circuit communicates with the host computer touch screen. Storage module, used for parameter storage; Among them, the PWM conversion circuit includes a MOSFET circuit for processing the stability of the square wave signal, a voltage stabilization circuit connected to the MOSFET circuit and processing the voltage stability, a two-stage RC filter circuit for converting the square wave signal into a DC signal, and a voltage follower that generates an analog voltage signal after processing to control the oscillator.

2. The eight-channel pellet counting system according to claim 1, characterized in that: The MOSFET circuit of the PWM conversion circuit includes a first MOSFET, a second MOSFET, a resistor R17 and a resistor R29. The first MOSFET is connected to the resistor R17, the second MOSFET is connected to the resistor R29, the first MOSFET and the second MOSFET are connected in parallel, and the voltage stabilizing circuit includes a precision voltage stabilizing tube for voltage stabilization; the two-stage RC filter circuit includes a first RC filter circuit and a second RC filter circuit connected in series, the first RC filter circuit is connected to the precision voltage stabilizing tube, and the second RC filter circuit is connected to the voltage follower.

3. The eight-channel pellet counting system according to claim 2, characterized in that: It also includes a voltage anti-interference module and a reference voltage module for providing precise voltage for the analog circuit. The reference voltage module is connected to the main control chip module to generate a reference voltage for providing the voltage required for adjustment of the analog signal output module.

4. The eight-channel pellet counting system according to claim 3, characterized in that: The signal input module comprises a first detection unit for detecting whether there are bottles in the production line, a second detection unit for detecting whether the bottles are blocked, an emergency stop signal input unit and a standby detection unit.

5. The eight-channel pellet counting system according to claim 4, characterized in that: The first detection unit includes a sensor, a high-low circuit module for judging the high and low levels of the sensor signal input, a signal isolation module, and a signal indicator light for intuitively displaying whether it is a high level or a low level; the sensor serves as the input signal end, the high-low circuit is disconnected from the input signal of the sensor, and is processed by the signal isolation module to achieve signal anti-interference.

6. The eight-channel pellet counting system according to claim 1, characterized in that: The signal output module includes a signal output end MOS tube for receiving instructions from a main control chip, a MOS tube working status indicator light, and a solenoid valve control chip for receiving instructions from the signal output end MOS tube.

7. The eight-channel pellet counting system according to claim 1, characterized in that: The grating plate module communication includes a grating plate main control chip, a photoelectric signal transmitting end, and a photoelectric signal receiving end.

8. An eight-channel pellet counting machine system according to any one of claims 1 to 7, characterized in that: The following steps are involved: a) After receiving the start command from the host computer, the conveyor belt, vibration table and grating sensor are activated synchronously; b) The material falling signal is collected in real time through the grating counting board, and the main control chip performs cumulative counting; c) When the count reaches a preset threshold, a solenoid valve control signal and a vibration table adjustment signal are generated; d) Upload the device status to the touch screen interface in real time through the communication module; e) When receiving an emergency stop signal, cut off the power supply to all actuators and activate the status indicator alarm.

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