Implementation method of bamboo laminated wood digital system material preparation production line

Abstract

The invention provides an implementation method of a bamboo laminated wood digital system material preparation production line, and the method comprises the following steps: S1, pretreating a moso bamboo raw material through a laser diameter measuring instrument and an optical sorting machine, and screening moso bamboos with the diameter of 8-12cm and the curvature of less than or equal to 5%; s2, the moso bamboo is cut in a segmented mode through a five-axis numerical control cutting machine, the angle of a tool bit is adjusted in real time according to cutting parameters according to the taper of the moso bamboo, and the end loss rate is smaller than or equal to 3%; s3, a multi-station parallel machining table is used for conducting green removing and thickness fixing machining on the cut moso bamboo sections, and the machining rhythm and the cutting rhythm are synchronously matched; s4, collecting a moso bamboo surface image through an industrial camera, performing quality judgment based on an AI crack recognition algorithm, enabling qualified products to enter a storage line, and sorting unqualified products to a recovery line; s5, the central control system dynamically allocates computing power resources; by optimizing the outturn percentage, the production speed and the quality control algorithm, efficient and accurate moso bamboo processing is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of bamboo processing, in particular to a method for realizing a feeding production line of a bamboo laminated lumber digital system. Background Art

[0002] Traditional bamboo stock preparation has problems such as low yield (usually less than 60%), high dependence on manual labor, and unstable quality. In the prior art, the cutting, sorting, and processing links are scattered and lack digital collaboration, resulting in low efficiency. Summary of the Invention

[0003] In view of this, the purpose of the present invention is to provide a method for realizing a feeding production line of a bamboo laminated lumber digital system that can achieve efficient and precise processing of moso bamboo by optimizing the yield, production speed, and quality control algorithm.

[0004] The present invention is realized by the following method: A method for realizing a feeding production line of a bamboo laminated lumber digital system, the method comprising the following steps:

[0005] Step S1, preprocessing moso bamboo raw materials through a laser diameter gauge and an optical sorter, and screening moso bamboos with a diameter of 8 - 12 cm and a bending degree ≤ 5%;

[0006] Step S2, segmenting and cutting the moso bamboo with a 5-axis numerical control cutting machine, and adjusting the tool head angle in real time according to the taper of the moso bamboo so that the end loss rate ≤ 3%;

[0007] Step S3, using a multi-station parallel processing table to perform de-greening and thickness-setting processing on the cut moso bamboo segments, and synchronizing the processing rhythm with the cutting rhythm;

[0008] Step S4, collecting the surface image of the moso bamboo through an industrial camera, performing quality determination based on the AI crack recognition algorithm, and the qualified products enter the storage line, while the unqualified products are sorted to the recycling line;

[0009] Step S5, the central control system dynamically allocates computing power resources, the quality inspection task occupies 60% - 80% of the GPU computing power, and the cutting path optimization occupies 20% - 30% of the CPU computing power, and monitors the fluctuation of the qualified rate in real time.

[0010] Further, the specific implementation method of the taper compensation cutting is as follows: Install a pressure sensor on the tool head of the cutting machine to detect the pressure value on the outer wall of the moso bamboo in real time; when the pressure value deviation exceeds the set threshold (±5 N), automatically adjust the tool head inclination angle, and the compensation formula is: θ = k·ΔP + θ0, where θ is the compensation angle, k is the calibration coefficient (0.1 - 0.3), ΔP is the pressure deviation value, and θ0 is the initial inclination angle.

[0011] Further, the AI crack recognition algorithm includes the following steps: Use the YOLOv5 model to detect cracks in the surface image of moso bamboo. The training dataset contains 5,000 bamboo images with marked cracks. Set the judgment threshold: When the crack length > 2 mm or the width > 0.1 mm, it is marked as unqualified. Update the model parameters every 30 minutes to adapt to the texture changes of different batches of moso bamboo.

[0012] Further, the dynamic computing power allocation satisfies the following conditions: When the system detects that the unqualified rate is ≥ 5% continuously for 10 minutes, automatically increase the quality inspection computing power to 80%, and at the same time reduce the cutting speed by 10%; When the qualified rate is stable ≥ 95% for 1 hour, restore the default computing power allocation ratio.

[0013] Further, the daily processing capacity of the production line is 60 tons of moso bamboo, the yield rate ≥ 70%, the surface roughness Ra of qualified products ≤ 6.3 μm, and the length error ≤ ±1 mm.

[0014] Further, after the step S2, there is also a counting mechanism for counting the moso bamboo segments after cutting. The counting mechanism includes a roller conveyor belt. Screws are spirally embedded at the left and right ends of the front and rear support plates of the roller conveyor belt. A push block is arranged at the end of the screw. A limit plate is arranged at the end of the push block. A first sliding opening is formed in the middle of the limit plate. A moving plate is arranged on the limit plate. Second sliding openings corresponding to the first sliding opening are formed at the front and rear ends of the moving plate. The first sliding opening and the second sliding opening are connected and fixed by bolts. The first sliding opening and the second sliding opening are communicated. A telescopic cylinder is arranged on the upper surface of the moving plate. A lifting plate is arranged at the end of the telescopic rod of the telescopic cylinder. An L-shaped lifting plate is arranged at the left end of the lower surface of the lifting plate. A sliding convex part is arranged on the right side surface of the vertical plate of the L-shaped lifting plate. A sliding groove is formed on the left side surface of the moving plate, and the sliding convex part is embedded in the sliding groove. A limit groove is formed at the left end of the lower surface of the horizontal plate of the L-shaped lifting plate. A swing block is hinged in the limit groove. A rubber counting rod is arranged on the lower surface of the swing block. A counting sensor is embedded at the right end in the limit groove. A display screen is arranged at the right end of the upper surface of the moving plate. The display screen is electrically connected to the counting sensor.

[0015] The beneficial effects of the present invention are as follows: By integrating sensors, computing power distribution algorithms, and dynamic quality monitoring, the present invention proposes a full-automatic digital production line solution; by optimizing the material yield, production speed, and quality control algorithms, efficient and precise processing of moso bamboo is achieved; a high material yield (70%+), high qualification rate (95%+), and a production capacity of 60 tons per day are realized in bamboo material preparation, filling the automation gap in the industry; through taper compensation and real-time sorting, the end loss rate is ≤3%, and the overall material yield is >70%; the AI quality inspection accuracy is >99%, and the system comprehensive qualification rate is stably maintained at 95%-98%; the daily processing capacity of a single line is 60 tons of moso bamboo, with the efficiency increased by 300% compared to traditional manual lines; the waste rate is reduced by 15%, and the annual cost savings exceed 2 million yuan. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic flowchart of the method of the present invention.

[0017] Figure 2 It is a schematic structural diagram of the counting mechanism.

[0018] Figure 3 It is the front view of the counting mechanism. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0019] The present invention will be further described below with reference to the accompanying drawings.

[0020] Example 1: Operating Process of Bamboo Glulam Stock Preparation Production Line

[0021] Input Parameters

[0022] Raw materials: 60 tons of moso bamboo, with an average diameter of 10 cm and a length of 6 m. The weight of a single piece is calculated as follows:

[0023] Volume = πr 2 h = 3.14 × (5 cm) 2 × 600 cm = 47100 cm 3 ;

[0024] Weight = 47100 cm 3 × 0.8 g / cm 3 = 37.68 kg;

[0025] Number of pieces processed per day: 60000 kg ÷ 37.68 kg / piece ≈ 1592 pieces 60000 kg ÷ 37.68 kg / piece ≈ 1592 pieces

[0026] Processing Process

[0027] Pretreatment: Sort and remove moso bamboo with a diameter < 8 cm or > 12 cm (accounting for about 5%), and the remaining 1512 pieces enter the cutting unit;

[0028] Cutting stage: The 5-axis cutting machine runs at a speed of 5 segments per minute. Each bamboo pole is cut into 25 segments (24 cm long per segment), taking 5 minutes per pole.

[0029] Please continue to refer to Figure 2 and Figure 3 As shown, in an embodiment of the present invention, after the step S2, a counting mechanism 1 for counting the cut bamboo segments is further provided. The counting mechanism 1 includes a roller conveyor belt 11. Screws 12 are spirally embedded at the left and right ends of the front and rear support plates of the roller conveyor belt 11. A push block 13 is provided at the end of the screw 12. A limiting plate 14 is provided at the end of the push block 13. A first sliding opening 15 is formed in the middle of the limiting plate 14. A moving plate 16 is mounted on the limiting plate 14. Second sliding openings 17 corresponding to the first sliding opening 15 are formed at the front and rear ends of the moving plate 16. The first sliding opening 15 and the second sliding opening 17 are connected and fixed by a bolt 2. The first sliding opening 15 and the second sliding opening 17 are communicated. A telescopic cylinder 3 is provided on the upper surface of the moving plate 16. A lifting plate 31 is provided at the end of the telescopic rod of the telescopic cylinder 3. An L-shaped lifting plate 32 is provided at the left end of the lower surface of the lifting plate 31. A sliding convex portion 33 is provided on the right side surface of the vertical plate of the L-shaped lifting plate 32. A sliding groove 34 is formed on the left side surface of the moving plate 16, and the sliding convex portion 33 is embedded in the sliding groove 34. A limiting groove 35 is formed at the left end of the lower surface of the horizontal plate of the L-shaped lifting plate 32. A swinging block 36 is hinged in the limiting groove 35. A rubber counting rod 37 is provided on the lower surface of the swinging block 36. A counting sensor 38 is embedded at the right end in the limiting groove 35. A display screen 4 is provided at the right end of the upper surface of the moving plate 16. The display screen 4 is electrically connected to the counting sensor 38. The cut bamboo segments are conveyed by the roller conveyor belt 11, and then the front and rear distances of the limiting plate 14 are adjusted by the screws 12 to realize the limiting function of the bamboo segments. Then, the telescopic cylinder 3 can drive the lifting plate 31 to lift. When the bamboo segments are conveyed, they pass through the rubber counting rod 37. The rubber counting rod 37 can drive the swinging block 36 to swing. The swinging of the swinging block 36 can contact the counting sensor 38, so that the number of passed bamboo segments can be measured and displayed through the display screen 4, thereby counting the cut bamboo segments and facilitating subsequent operations.

[0030] The telescopic cylinder, roller conveyor belt, counting sensor, and display screen in the present invention are all prior arts, and those skilled in the art have been able to clearly understand them, so no detailed description is given here. The counting sensor can be E32-HB04, but is not limited thereto.

[0031] The hinge setting in the present invention is the hinge method in the prior art, and those skilled in the art have been able to clearly understand it, so no detailed description is given here.

[0032] Processing stage: The multi-station processing table synchronously processes 5 bamboo poles, taking 1 minute per batch and processing 300 poles per hour.

[0033] Quality inspection stage: The industrial camera captures surface images at a speed of 200 frames per second, and the AI model makes real-time judgments. The quality inspection time for each single pole is 0.3 seconds.

[0034] Output result

[0035] Qualified products: 1512 poles × 70% yield rate = 1058 poles → The converted weight is 1058 × 37.68 kg ≈ 40 tons 1058 × 37.68 kg ≈ 40 tons;

[0036] Unqualified products: 454 poles, among which 30% can be reprocessed. The final waste rate is 454 × 70% = 318 poles ≈ 12 tons 454 × 70% = 318 poles ≈ 12 tons;

[0037] Qualified rate: The system statistics show that the qualified rate on the same day is 97.3% (the quality inspection module records 41 defective bamboo poles).

[0038] Verification of key parameters

[0039] Yield rate: 40 tons ÷ 60 tons × 100% = 66.7% 40 tons ÷ 60 tons × 100% = 66.7% (actually increased to 70% due to reprocessing);

[0040] Production speed: Processing 300 poles per hour, reaching the design index;

[0041] Quality compliance: Randomly inspect 100 qualified products, and the length error is within ±0.8 mm, and the surface roughness Ra ≤ 5.6 μm.

[0042] Economic benefits

[0043] The yield rate of the traditional process is 55%, and this invention has increased it to 70%. The daily additional output of bamboo is 60 tons × (70% - 55%) = 9 tons 60 tons × (70% - 55%) = 9 tons;

[0044] Calculated at the unit price of bamboo of 3000 yuan per ton, the annual increased efficiency is 9 tons × 3000 yuan × 300 days = 8.1 million yuan 9 tons × 3000 yuan × 300 days = 8.1 million yuan;

[0045] After deducting the equipment energy consumption and maintenance cost of 6 million yuan, the net cost savings is 2.1 million yuan per year.

[0046] Example 2: Practical application of dynamic computing power allocation

[0047] Scenario: One day, the quality inspection module detected that 20 consecutive bamboo poles had cracks, and the unqualified rate suddenly increased to 8%;

[0048] System response:

[0049] The central control module increases the GPU computing power from 60% to 80%, and the AI model detection frequency is increased by 33%;

[0050] The cutting machine reduces its speed by 10% to ensure in-depth quality inspection;

[0051] After 30 minutes, the unqualified rate drops back to 3%, and the system resumes the default computing power allocation.

[0052] The above are only the preferred embodiments of the present invention. All equivalent changes and modifications made according to the scope of the patent application of the present invention shall fall within the scope covered by the present invention.

Claims

1. A method for implementing a stock preparation production line of a bamboo laminated lumber digital system, characterized in that, The method includes the following steps: Step S1: Pretreat the moso bamboo raw materials through a laser diameter gauge and an optical sorting machine, and screen the moso bamboos with a diameter of 8 - 12 cm and a bending degree ≤ 5%; Step S2: Use a 5-axis CNC cutting machine to cut the moso bamboo into segments. The cutting parameters adjust the tool head angle in real time according to the taper of the moso bamboo to make the end loss rate ≤ 3%; Step S3: Use a multi-station parallel processing table to perform de-greening and thickness determination processing on the cut moso bamboo segments, and the processing rhythm is synchronized with the cutting rhythm; Step S4: Collect the surface image of the moso bamboo through an industrial camera, and conduct quality determination based on the AI crack recognition algorithm. The qualified products enter the warehousing line, and the unqualified products are sorted to the recycling line; Step S5: The central control system dynamically allocates computing power resources. The quality inspection task occupies 60% - 80% of the GPU computing power, and the cutting path optimization occupies 20% - 30% of the CPU computing power, and monitors the fluctuation of the qualified rate in real time.

2. The implementation method of a bamboo laminated lumber digital system stock preparation production line according to claim 1, characterized in that: The specific implementation method of the taper compensation cutting is as follows: Install a pressure sensor on the tool head of the cutting machine to detect the pressure value on the outer wall of the moso bamboo in real time; when the pressure value deviation exceeds the set threshold (±5N), automatically adjust the tool head inclination angle, and the compensation formula is: θ = k·ΔP + θ0, where θ is the compensation angle, k is the calibration coefficient (0.1 - 0.3), ΔP is the pressure deviation value, and θ0 is the initial inclination angle.

3. The implementation method of a bamboo laminated lumber digital system stock preparation production line according to claim 1, characterized in that: The AI crack recognition algorithm includes the following steps: Use the YOLOv5 model to detect cracks in the surface image of the moso bamboo. The training data set contains 5000 bamboo images with marked cracks; set the determination threshold: when the crack length > 2 mm or the width > 0.1 mm, it is marked as unqualified; update the model parameters every 30 minutes to adapt to the texture changes of different batches of moso bamboos.

4. The implementation method of a bamboo laminated lumber digital system stock preparation production line according to claim 1, characterized in that: The dynamic computing power allocation meets the following conditions: When the system detects that the unqualified rate is ≥ 5% continuously for 10 minutes, automatically increase the quality inspection computing power to 80%, and at the same time reduce the cutting speed by 10%; when the qualified rate is stable ≥ 95% for 1 hour, restore the default computing power allocation ratio.

5. A method for implementing a stock preparation production line of a bamboo laminated lumber digital system according to any one of claims 1-4, characterized in that: The daily processing capacity of the production line is 60 tons of moso bamboo, the yield rate ≥ 70%, the surface roughness Ra of the qualified products ≤ 6.3 μm, and the length error ≤ ±1 mm.

6. The implementation method of a bamboo laminated lumber digital system stock preparation production line according to claim 1, characterized in that: It further includes a counting mechanism for realizing the counting of the cut bamboo sections, which is arranged after the step S2. The counting mechanism includes a roller conveyor belt. Screws are spirally embedded at the left and right ends of the front and rear support plates of the roller conveyor belt. A pushing block is arranged at the end of the screw, and a limiting plate is arranged at the end of the pushing block. A first sliding opening is formed in the middle of the limiting plate. A moving plate is arranged on the limiting plate. Second sliding openings corresponding to the first sliding opening are formed at the front and rear ends of the moving plate. The first sliding opening and the second sliding opening are connected and fixed by bolts, and the first sliding opening and the second sliding opening are communicated. A telescopic cylinder is arranged on the upper surface of the moving plate. A lifting plate is arranged at the end of the telescopic rod of the telescopic cylinder. An L-shaped lifting plate is arranged at the left end of the lower surface of the lifting plate. A sliding convex part is arranged on the right side surface of the vertical plate of the L-shaped lifting plate. A sliding groove is formed on the left side surface of the moving plate, and the sliding convex part is embedded in the sliding groove. A limiting groove is formed at the left end of the lower surface of the horizontal plate of the L-shaped lifting plate. A swinging block is hinged in the limiting groove. A rubber counting rod is arranged on the lower surface of the swinging block. A counting sensor is embedded at the right end in the limiting groove. A display screen is arranged at the right end of the upper surface of the moving plate, and the display screen is electrically connected with the counting sensor.

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