Bag supply method of automatic sorting machine

Abstract

The invention relates to the technical field of automatic sorting, in particular to a package supply method of an automatic sorting machine, which is characterized in that goods and sorting instructions are marked through position information of a storage unit of the sorting machine as a main thought, and abnormity perception performed by a low-cost simple sensor is used as a supplement, and the package supply method of the automatic sorting machine comprises software and also comprises hardware, the system is generally called a packet supply system. Software and hardware of the package supply system can operate independently and can also be flexibly embedded into a sorting machine system or an upper system. The automatic sorting machine is suitable for various common automatic sorting machines at present. The method is suitable for sorting scenes for preparing package supply for the automatic sorting machine on site according to needs, such as fresh food distribution, supermarket distribution and the like. Compared with a conventional method of marking goods with codes, code scanning equipment is not needed, the package supply preparation operation cost can be reduced, the goods recognition rate (especially goods with irregular shapes) can be increased, the abnormal processing operation cost caused by the package supply preparation operation cost can be reduced, basic conditions for goods package supply abnormal intelligent processing are provided, the hardware cost is reduced, and the compatibility of an automatic sorting machine is enhanced; and the low-cost sensor is used for realizing multi-cargo and insufficient-cargo detection and ensuring low error rate.

Description

Technical Field

[0001] The present invention relates to the technical field of automatic sorting, and particularly to a bag supply method for an automatic sorting machine. Background Art

[0002] With the development of e-commerce, order processing and sorting efficiency have become important links in logistics distribution. Traditional cross-regional and cross-organizational collaborative sorting methods represented by express logistics usually require barcodes to be attached to each item, and automatic sorting is performed by scanning the codes. When this method is applied to scenarios such as fresh food distribution and supermarket distribution that require on-site bag supply preparation according to demand, due to the irrationality of the process method, it not only increases equipment costs, material costs such as barcodes and packaging materials, and operation costs, but also reduces sorting efficiency and limits the scope of application. Especially for items with irregular shapes and bulk items that do not need to be packaged in this link, the traditional "labeling goods with barcodes" sorting method is particularly inconvenient.

[0003] Taking the common "three-stage bag supply table" as an example, after receiving the bag supply instruction, the bag supplier needs to perform packaging and "barcode labeling" in addition to preparing the goods. After barcode labeling, the goods are placed flat enough on the first stage for barcode scanning. After barcode scanning, they are transferred to the second stage for weighing (not "weighing according to demand" but "weight data collection"), and after weighing, they are transferred to the third stage for intermittent bag supply. This approach not only adds unnecessary operation links such as packaging, barcode labeling, and flat placement, but also uses unnecessary barcode scanning equipment and weighing equipment (not required in most scenarios), and further increases the problem of low recognition rate of irregular items due to barcode scanning. Finding a method to skip these redundant links, improve efficiency, reduce costs, and expand the scope of application of automatic sorting machines has become the key direction for the logistics sorting industry to solve. For this reason, we propose a bag supply method for an automatic sorting machine. Summary of the Invention

[0004] Based on the technical problems existing in the background art, the present invention proposes a bag supply method for an automatic sorting machine, which can achieve item labeling in terms of time and space and detect item abnormalities without attaching barcodes, improve the item recognition rate, and solve the problems in the prior art that not only add unnecessary operation links such as packaging, barcode labeling, and flat placement, but also use unnecessary barcode scanning equipment and weighing equipment (not required in most scenarios), and further increase the problem of low recognition rate of irregular items due to barcode scanning.

[0005] The present invention provides the following technical solution: A bag supply method for an automatic sorting machine includes the following steps:

[0006] S1. The sorting machine system obtains equipment operation information through an encoder, and synchronizes the equipment operation information and item position information to the upper-level system, and the upper-level system records the sorting machine operation information and item position information;

[0007] S2. After the supplier prepares for supply at a specific supply position according to the instructions of the upper-level system, when the sorting machine storage unit in front of the supply position is idle, the goods are placed therein.

[0008] S3. The goods trigger the sensor, and the sensor signal is directly forwarded to the upper-level system or via the sorting machine system.

[0009] S4. After receiving the sensor signal, the upper-level system performs cross-verification of multi-sensor signals. When there is a change, it notifies the sorting machine system, and the sorting machine system records and updates the supply information and sorting information.

[0010] S5. When the upper-level system determines that the supply information or sorting information is incorrect, it issues an error warning and executes the error handling process.

[0011] S6. According to the recorded sorting information, the sorting machine system sorts the goods in the sorting machine storage unit to the designated grid and notifies the upper-level system of the sorting result.

[0012] This method is applicable to sorting scenarios where supply preparation is made for the automatic sorting machine on-site as needed (according to instructions), such as fresh food distribution, supermarket distribution, etc. In most of these scenarios, most goods are not processed upstream to the final required weight / quantity / form downstream. For goods that have been processed upstream to the final required weight / quantity / form downstream, this method can also be combined with conventional methods such as "labeling goods with codes" in the supply system, so that this method is applicable to more business scenarios.

[0013] Preferably, in step S3, the sensor includes a supply sensor and a goods information sensor. The supply action of placing the goods in the sorting machine storage unit triggers the supply sensor, or the goods information sensor is triggered when the goods pass by the goods information sensor on the sorting machine.

[0014] The input / output hardware devices of the supply system can be independently operated in implementation, or can be flexibly integrated into the sorting machine system or the upper-level system, and can be combined with software configuration to flexibly change positions without affecting the stable operation of the supply system, so as to better support the characteristics of the flexible embedding of the supply system software and hardware into the sorting machine system or the upper-level system.

[0015] The input / output hardware devices include a bag feeding sensor, a goods information sensor, and a bag feeding position information display device. Among them, the bag feeding sensor and the goods information sensor can well meet the requirements of the business scenario by using simple and low-cost photoelectric switches, proximity switches, limit switches, pressure switches, etc., and can also be extended to other single or integrated sensor devices such as visual recognition, volume recognition, weight recognition, etc. The bag feeding position information display device can use optical devices such as small lights and screens, or / and use devices such as sound and vibration, and can share with the bag feeding instruction display device at the bag feeding position to better support the detection characteristics of bag feeding signals, multiple goods, and shortage of goods through simple and low-cost sensors.

[0016] Preferably, the sensor in step S3 approximately calculates the width of the goods by combining the on / off duration data of the photoelectric switch with the operating speed.

[0017] Preferably, the sensor in step S3 determines whether there is goods through the on / off data of the pressure switch. Through simple and low-cost sensors, combined with the operating information of the sorting machine system, the detection of multiple goods and shortage of goods is realized, so as to ensure an extremely low error rate while operating efficiently; and it can also be combined with the operating information of the sorting machine system and the position information of other goods in the sorting machine storage unit to provide the possibility of intelligent processing of abnormal bag feeding of goods for the upper-level system.

[0018] Preferably, the sensor in step S3 detects the bag feeding action through a proximity switch, generates image data for analysis through visual recognition, or directly generates category or volume data. On the premise of "bag feeding preparation" on-site as required (according to the instruction) and using an automatic sorting machine for sorting, the bag feeding sensor is triggered simultaneously with the bag feeding action. At this time, the goods and the sorting machine storage unit are in the same position as the bag feeding sensor, and the sorting information of the goods is included in the bag feeding instruction at this time. Therefore, each system has the ability to obtain the "Internet of Things" information of "this goods in this sorting machine storage unit at this time and place". The concept of the sorting machine storage unit includes the trolley unit of the cross-belt sorting machine, the storage position of the conveyor belt, the chute of the slider sorting machine, etc.

[0019] Preferably, the sensor in step S3 generates volume data through an infrared volume sensor and detects the weight of the goods through a gravity sensor.

[0020] Preferably, in step S5, on the premise that the error result of the bag feeding signal has been received, the bag feeding position error signal display ability is available, and it has been set to be displayed on this path in the software configuration, the upper-level system, the bag feeding system, and the sorting machine system can all be used as the display path of the bag feeding signal error, and different display methods selected by the software configuration within the ability range are used;

[0021] When there is information about goods but there are actually no goods, replenish the goods or find the missing goods; when there is information about no goods but there are actually goods, handle the excess goods.

[0022] The software implementation of the bag supply system can run independently or be flexibly embedded in the sorting machine system or the upper-level system for operation; the "flexibility" here means: in terms of the operation mode, it can run independently, or can be safely run in a sandbox as a component of the sorting machine system or the upper-level system, or can also run together with the host system in the "source code + SDK" mode; it also means: at the communication protocol layer, it can adapt to conventional communication protocols such as 232, 485, Modbus, Socket, WebSocket, HTTP(s), RESTful API, gRPC, AMQP / MQTT used in the sorting machine system and the upper-level system, and can implement custom communication protocols to better support the characteristics of the flexible embedding of the software and hardware of the bag supply system in the sorting machine system or the upper-level system in this method.

[0023] Preferably, in step S3, when using an O-shaped cross-belt plus conveyor belt combination sorting machine, the bag supply sensor is arranged at the junction of the bag supply position and the storage unit of the sorting machine, and the goods information sensors are respectively arranged at the junction of the conveyor belt and the cross-belt sorting machine and in front of the abnormal grid opening on the main line of the O-shaped cross-belt sorting machine.

[0024] Due to the module independence of the sensor, the simplicity of the installation method, the flexibility of the installation position, and the flexibility of the communication protocol described in this method, it is thus adaptable to various common types of automatic sorting machines currently, including single-layer / multi-layer sorting machines, O-shaped / linear sorting machines, cross-belt / slider type / baffle type / emergence type / tilt type / hanging type / roller type / vertical sorting machines, continuous / intermittent sorting machines, and composite sorting machine clusters, to better support the characteristics of adapting to various common types of automatic sorting machines currently in this method.

[0025] The present invention provides a bag supply method for an automatic sorting machine. During the bag supply process, the bag supply sensor is triggered simultaneously with the bag supply action. At this time, the goods and the storage unit of the sorting machine are in the same position as the bag supply sensor. The sorting information of this goods is included in the bag supply instruction at this time and place, thereby distinguishing from the conventional method of "labeling goods by code", and further reducing the operation cost of bag supply preparation, improving the sorting recognition rate and accuracy of goods (especially irregularly shaped goods), reducing the hardware cost, and further enhancing the compatibility with the form of the sorting machine in such scenarios. This method can use simple and low-cost sensors to realize the detection of bag supply signals, overstock and understock, so as to ensure a very low error rate while operating efficiently, and combine the function of synchronizing the operation information of the sorting machine and the position information of other goods to provide the possibility of intelligent processing of goods abnormalities for the upper-level system under specific circumstances.

[0026] This method does not require a scanning device, which can reduce the cost of bagging preparation operations, improve the recognition rate of goods (especially goods with irregular shapes), reduce the cost of exception handling operations caused thereby, provide the basic conditions for intelligent handling of bagging exceptions of goods, reduce hardware costs, and enhance compatibility with automatic sorting machines; multi-goods and few-goods detection are achieved through low-cost sensors to ensure a low error rate. Brief Description of the Drawings

[0027] Figure 1 It is a flow chart of the method of the present invention;

[0028] Figure 2 It is a diagram of the sensor installation position in the method of the present invention. Detailed Embodiments

[0029] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, 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.

[0030] As Figure 1 shown, the present invention provides a technical solution: a bagging method for an automatic sorting machine, including the following steps:

[0031] S1. Synchronization of sorting machine system operation information and goods position information: The sorting machine system obtains equipment operation information through an encoder and synchronizes the equipment operation information and goods position information to the upper-level system. The upper-level system records the sorting machine operation information and goods position information for combination with bagging information, goods sorting instructions, etc.:

[0032] It provides the possibility of intelligent handling of goods exceptions for the upper-level system to serve as a supplementary method for exception situations of this bagging method.

[0033] It additionally provides capabilities such as digital twin and digital mapping for the upper-level system.

[0034] S2. Bagging operation: After the bagger prepares for bagging according to the instructions of the upper-level system at a specific bagging position, when the sorting machine storage unit in front of this bagging position is idle, the goods are placed therein, and this bagging action simultaneously triggers the bagging sensor. Or when the goods pass by the goods information sensor on the sorting machine, the goods information sensor is triggered.

[0035] The bagging sensor is arranged at the junction of the bagging position and the sorting machine storage unit.

[0036] The goods information sensor is arranged on the main line of the sorting machine.

[0037] The sensor can use simple and low-cost optoelectronic switches, and / or pressure switches, and / or proximity switches, or can be replaced / expanded with vision recognition, infrared volume recognition, gravity sensors, etc.

[0038] Parameters such as the position, quantity, type, installation method, installation location, and installation angle of the sensor need to be adapted according to the specific conditions of the sorting machine type, sorting machine system, upper-level system, etc.

[0039] Such as Figure 2 As shown, taking the O-shaped cross-belt plus conveyor belt combination sorting machine as an example, the supply package sensor A is arranged at the junction of the supply package position and the storage unit of the sorting machine, and the goods information sensors B and C are respectively arranged at the junction of the conveyor belt and the cross-belt sorting machine and in front of the abnormal grid opening on the main line of the O-shaped cross-belt sorting machine.

[0040] S3. Sensor signal transmission: The sensor signal is directly transmitted, or forwarded to the upper-level system via the sorting machine system.

[0041] Content of the sensor signal: The content includes the sensor number and the sensor signal data. The sensor signal data varies according to the sensor type: The data of the optoelectronic switch is the on-off duration, and the width of the goods can be approximately calculated by combining the running speed; the data of the pressure switch is on-off, which can be approximately translated as whether there is goods; for the proximity switch, it can be approximately understood as the supply package action; for vision recognition, it can generate image data for analysis, or directly generate type / volume data; the infrared volume sensor can generate volume data; the gravity sensor can be understood as the weight of the goods.

[0042] S4. Synchronization of supply package information / sorting information: After receiving the sensor signal, the upper-level system performs cross-verification of multi-sensor signals, and if there is a change, it notifies the sorting machine system. The sorting machine system records / updates the supply package information / sorting information.

[0043] By combining multiple information, it is possible to ensure the accuracy of the supply package information and sorting information without using high-cost equipment and complex algorithms. At the "supply package position", if the sensor only has a proximity switch, it cannot be directly used as the basis for judging "whether there is goods". At this time, it is necessary to combine "whether there is a supply package instruction" and approximately consider "whether the supply package has been carried out according to the instruction", and provide a revision opportunity to the supply packer to reduce the possibility of misoperation. It can also be further revised by combining the goods information sensor at the subsequent position.

[0044] At the subsequent position, due to the lack of human interference similar to the "supply package position", the data of the "goods information sensor" can be directly used as the basis for "whether there is goods".

[0045] If the supply package sorting information is generated or changed, it is necessary to notify the sorting machine system in a timely manner.

[0046] S5. Supply Package Information / Sorting Information Error: If the upper-level system determines that the supply package information / sorting information is incorrect, it issues an error warning and executes the error handling process.

[0047] Alarm Path and Method: On the premise that the error result of the supply package signal has been received, the supply package position error signal display ability is available, and it has been set in the software configuration to be displayed on this path, the upper-level system, the supply package system, and the sorting machine system can all be used as the display path of the supply package signal error, and different display methods selected in the software configuration within the ability range can be used. Optical devices such as small lights and screens can be used, or / and devices such as sound and vibration can be used, and can be shared with the supply package instruction display device at the supply package position.

[0048] Error Handling: In addition to alarming, the error handling process also includes information revision, goods handling, etc. When there is goods in the information but actually no goods, replenish the goods or find the missing goods; when there is no goods in the information but actually there are goods, handle the excess goods.

[0049] S6. The sorting machine performs sorting: The sorting machine system sorts the goods in the storage unit of the sorting machine to the designated compartments according to the recorded sorting information, and notifies the upper-level system of the sorting result.

[0050] In the present invention, there is no need to label the goods, which greatly reduces the operation cost of supply package preparation, label material cost, packaging material cost for meeting the code scanning conditions, and printing equipment cost. After testing, after using this method, in the supply package operation of fresh food and other food ingredient supply chains, the measured operation cost is reduced by 40-50%, accounting for about 2% of the overall transaction cost; the saved label cost, packaging material cost, and printing equipment cost account for about 0.2% of the transaction cost.

[0051] The present invention uses low-cost sensors to replace the code scanning equipment, reducing the hardware cost. After comparison, after using this method, in the supply package operation of fresh food and other food ingredient supply chains, the hardware cost of code scanning and supply package of the same scale can be reduced by more than 99%, accounting for about 0.8% of the overall transaction cost.

[0052] Compared with the "goods labeling with codes" solution of barcodes / QR codes, the present invention solves the problem of goods recognition rate, thereby reducing the operation cost of exception handling. After calculation, after using this method, in the supply package operation of fresh food and other food ingredient supply chains, the measured operation cost of exception handling is reduced by more than 90%, accounting for about 0.4% of the overall transaction cost.

[0053] Exceptions are particularly likely to occur in the following situations:

[0054] The operating speed of the sorting equipment exceeds the acceptable threshold of the recognition equipment;

[0055] The flatness, clarity, and size of barcodes / QR codes are not good enough;

[0056] The directivity and position of the barcode / QR code are not good enough, or it is blocked, contaminated, or covered;

[0057] The external lighting environment is not good enough;

[0058] For the "using codes to label goods" solutions such as RFID, the present invention reduces the high-cost label recycling operation cost; after measurement, in the fresh food supply chain bagging operation, the RFID label recycling operation cost accounts for about 0.2% of the overall transaction cost;

[0059] In the "sorting scenario of on-site bagging preparation for automatic sorting machines on demand", the present invention enhances the compatibility with various sorting machines and environmental compatibility because there is no need to consider the physical compatibility of the code scanning device; this method has been successfully applied to the combined sorting machine of cross-belt and conveyor belt (fresh food sorting and distribution), the combined sorting machine of slider and conveyor belt (supermarket fast-moving consumer goods sorting and distribution), the combined sorting machine of baffle and conveyor belt (factory parts order separation), and the hanging sorting machine (special fresh food sorting and distribution). Due to the independence, modular design, easy installation, and adaptability of the software protocol of this method, it can also be quickly adapted to other types of sorting machines.

[0060] The detection of overstock and understock is realized through the goods information sensor, which further ensures the extremely low error rate of the bagging operation.

[0061] The above is only the preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution and inventive concept of the present invention, makes equivalent substitutions or changes, and all should be covered within the protection scope of the present invention.

Claims

1. A package supply method for an automatic sorting machine, characterized in that: The steps include: S1. The sorting machine system will obtain the equipment operation information through the encoder, and synchronize the equipment operation information and the goods location information to the upper system, and the upper system will record the sorting machine operation information and the goods location information; S2. The package supplier prepares the package supply at a specific package supply position according to the instructions of the upper system, and places the goods in the sorter storage unit in front of the package supply position when the storage unit is free; S3. Goods trigger sensors, and sensor signals are forwarded to the upper system directly or via the sorting machine system; S4. After receiving the sensor signal, the upper system performs multi-sensor signal cross-verification. When there is a change, the sorting machine system is notified, and the sorting machine system records and updates the package supply information and sorting information; S5. When the upper system determines that the package supply information or sorting information is wrong, it issues an error alarm and executes the error handling process; S6. The sorting machine system sorts the goods in the sorting machine storage unit to the designated grid according to the recorded sorting information, and notifies the upper system of the sorting result.

2. The package supply method for an automatic sorting machine according to claim 1, characterized in that: In step S3, the sensors include a package supply sensor and a product information sensor. The package supply sensor is triggered simultaneously when the product is placed in the storage unit of the sorting machine, or the product information sensor is triggered when the product passes through the product information sensor on the sorting machine.

3. The method for supplying packages to an automatic sorting machine according to claim 1, characterized in that: The sensor in step S3 calculates the width of the goods approximately through the on-off duration data of the photoelectric switch combined with the operating speed.

4. The package supply method for an automatic sorting machine according to claim 1, characterized in that: The sensor in step S3 interprets the on / off data of the pressure switch as whether goods exist.

5. The package supply method for an automatic sorting machine according to claim 1, characterized in that: The sensor in step S3 detects the package feeding action through a proximity switch and generates image data for analysis through visual recognition, or directly generates type or volume data.

6. The package supply method for an automatic sorting machine according to claim 1, characterized in that: The sensor in step S3 generates volume data through an infrared volume sensor and detects the weight of the goods through a gravity sensor.

7. The package supply method for an automatic sorting machine according to claim 1, characterized in that: In step S5, on the premise that the packet supply signal error result has been received, the packet supply position error signal display capability is available, and the software configuration has been set for the path display, the upper system, the packet supply system, and the sorter system can all serve as display paths for the packet supply signal error, and use different display methods selected by the software configuration within the capability range; When the information shows that the goods are in stock but they are actually out of stock, replenish the goods or find the missing goods; when the information shows that the goods are out of stock but they are actually in stock, handle the excess goods.

8. The package supply method for an automatic sorting machine according to claim 1, characterized in that: In step S3, when an O-type cross belt plus conveyor belt combined sorting machine is used, the package supply sensor is arranged at the junction of the package supply position and the sorting machine storage unit, and the product information sensors are respectively arranged at the junction of the conveyor belt and the cross belt sorting machine and in front of the abnormal grid on the main line of the O-type cross belt sorting machine.

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