Automatic discharging and transferring method for PET (Polyester) film roll

Abstract

The invention discloses a polyester PET (polyethylene terephthalate) film roll automatic blanking sequence turning method, which relates to the technical field of polyester film roll production automation, and comprises the following steps: S1, receiving a blanking instruction from a production management system by using a truss robot, taking out a polyester PET film roll from a rolling station by using the truss robot after a laminating machine finishes production of the polyester PET film roll, and taking out the polyester PET film roll from the rolling station; placing on a special tray provided with a positioning and limiting structure; and S2, when the truss robot completes the discharging action, the discharging control system generates a discharging completion signal, and the signal is sent to the AGV dispatching system through the intermediate communication interface. According to the invention, high-reliability synchronous control between the truss robot and the AGV system is realized, and closed-loop execution of tasks is ensured; an anomaly detection and task rollback mechanism is provided, so that the fault tolerance and continuous operation capability of the system is improved; a dynamic scheduling and prediction algorithm is introduced, AGV resource allocation and path planning are optimized, and the production efficiency and the system stability are comprehensively improved.

Description

Technical Field

[0001] The present invention relates to the technical field of polyester film roll production automation, and specifically relates to an automatic blanking and transfer method for polyester PET film rolls. Background Art

[0002] "Automatic blanking and transfer of polyester PET film rolls" refers to a complete set of intelligent processes in the production process of polyester PET film rolls, in which heavy film rolls after being produced by a coating machine are unloaded from the equipment through automated equipment (such as a gantry robot), and are transported and distributed according to a preset order, stacking method, and logistics path. This method combines special fixtures, pallet design, and an AGV forklift system, can identify film rolls of different specifications, and realizes the automatic unloading of the material roll from the coating machine, stable stacking on the pallet, and precise transfer to subsequent curing or storage processes, thus avoiding problems such as low efficiency and chaotic scheduling in traditional manual operations, ensuring the efficient and orderly connection between each process of the entire production line, and at the same time improving the flexibility and automation level of the production line.

[0003] The prior art has the following deficiencies: In the process of automatic blanking and transfer of polyester PET film rolls in the prior art, there is a key control problem, that is, the instruction synchronization between the blanking control system of the gantry robot and the AGV scheduling system fails. This problem is manifested at the control level as time delay or data loss in the task scheduling logic, resulting in the failure of the AGV to take over the pallet transfer task in time after the robot completes the blanking operation, thus causing pallet accumulation at the blanking station, disorder of the production rhythm, and even possible equipment operation conflicts or collision accidents. Such problems usually stem from network transmission delays, inconsistent scheduling logics, or abnormal intermediate communication interfaces, which have a very serious impact on the continuous-operation automated production line and are prone to cause systemic stagnation and production capacity losses. Therefore, building a highly reliable and highly real-time control coordination mechanism is the core technical challenge to ensure the stable operation of the automatic blanking and transfer system.

[0004] The above information disclosed in the background art section is only used to enhance the understanding of the background of the present disclosure, and therefore it may include information that does not constitute the prior art known to those of ordinary skill in the art. Summary of the Invention

[0005] The object of the present invention is to provide an automatic blanking and transfer method for polyester PET film rolls, which realizes high-reliability synchronous control between the gantry robot and the AGV system, ensures the closed-loop execution of tasks; has an abnormal detection and task rollback mechanism, improves the fault tolerance and continuous operation ability of the system; introduces a dynamic scheduling and prediction algorithm, optimizes the AGV resource allocation and path planning, and comprehensively improves the production efficiency and system stability, so as to solve the problems in the above background art.

[0006] To achieve the above object, the present invention provides the following technical solution: An automatic blanking and transfer method for polyester PET film rolls, comprising the following steps: S1. The gantry robot receives the blanking instruction from the production management system. After a roll of polyester PET film is produced by the film laminating machine, the gantry robot takes the film roll out from the winding station and places it on a special tray equipped with a positioning and limiting structure. S2. While the gantry robot completes the blanking operation, the blanking control system generates a blanking completion signal, which is sent to the AGV scheduling system through the intermediate communication interface. S3. After receiving the blanking completion signal, the AGV scheduling system calls the preset path rule and transfer sequence priority strategy, selects the corresponding idle AGV forklift from the AGV task pool, and assigns it to execute the current transfer task. S4. The AGV forklift travels to the blanking station according to the specified path navigation system. After automatically identifying the tray barcode and confirming the load information, it loads the tray together with the film roll onto the vehicle body. S5. The AGV forklift accurately transports the film roll tray to the specified curing furnace inlet or temporary buffer area according to the task instruction in the MES system, and the task execution status is uploaded to the warehouse management system in real time. S6. After the AGV completes the transfer task, the control system of the gantry robot resets and enters the standby state. After receiving the blanking instruction for the next roll of film, it repeats S1 to S5 to ensure operation under closed-loop logic control and avoid scheduling conflicts.

[0007] Preferably, the gantry robot adopts a three-axis linkage structure, corresponding to the axis, axis and axis directions respectively, and integrates a set of variable-position handling fixtures. The fixtures have two functions: one is to hook the core shaft of the film roll through the rotating hook structure to achieve heavy-load lifting; the other is to grab the core shaft through the parallel jaw structure to complete the extraction and insertion actions. Whenever the robot performs the pre-blanking action, its control system automatically adjusts the fixture spacing according to the film roll diameter and core shaft length data issued by the MES to ensure handling stability and blanking accuracy.

[0008] Preferably, the tray is provided with a two-way limiting groove structure and adjustable wedge-shaped limit blocks. Each tray surface is preset with three symmetrically distributed limiting tracks for stacking three rolls of film in a "pin" shape. Each wedge-shaped limit block is connected to the track through a sliding buckle device, and the sliding distance is accurately marked by the coding scale at the bottom of the tray. When the gantry robot performs the stacking action, it automatically calls the limit block displacement program according to the film roll specifications, so that both ends of each film roll are stably supported by the limit blocks. The limiting structure also has an anti-seismic buffer cushion layer, which can effectively absorb the micro-vibrations generated during transportation, prevent the film roll from shifting or tipping over, and thus ensure the stacking safety and transfer stability.

[0009] Preferably, a multi-system synchronous control logic module is provided in the control system. The core of the module is the timestamp synchronization algorithm. Each blanking event will record an accurate timestamp after the truss robot completes the last action node. The response time of the AGV scheduling system after receiving the signal is denoted as If , is the time difference, the control system will trigger a synchronization exception handling mechanism to automatically start a standby AGV or resend the instruction to avoid task backlog.

[0010] Preferably, to ensure the stability of system scheduling and the accuracy of response time, a scheduling response correction mechanism based on PID + prediction algorithm is added to the control system. The specific steps are as follows: Set the task signal delay target value , and the currently measured system delay is . Define the error term, and the calculation expression is as follows: , where is the error term; Set the proportional coefficient , integral coefficient , and differential coefficient . Calculate the adjustment parameter, and the calculation expression is as follows: , where is the proportional coefficient, which is used to determine the direct proportional relationship of the error term in the control output, is the integral coefficient, which is used to accumulate the trend of error accumulation over time and eliminate the static error, is the differential coefficient, which is sensitive to the change speed of the error and is used to predict the trend in advance, is the adjustment signal given by the PID controller at time , is the virtual time variable, which represents a scanning variable from the starting time 0 to time , is the system error at each time point , is the small time increment; Use the time series prediction model AR(1) to estimate the delay in the next cycle. The delay formula calculation expression is as follows: , where is the predicted delay in the next cycle, is the autocorrelation coefficient of the delay, is the model offset correction amount; Adjust the thread scheduling priority of the signal transfer server. The formula is as follows: , where It is a comprehensive index of scheduling priority; When it is a preset tolerance threshold, which triggers the main control system to switch to the standby relay server to ensure the continuity of instruction transmission and the real-time response.

[0011] Preferably, during the execution of the blanking transfer task, the AGV scheduling priority is optimized in real time, and the specific steps are as follows: Let the weight of the film roll be , and the weight of the tray be , calculate the total load, and the calculation expression is as follows: , where is the total load weight; Let the estimated time for the film roll to come out of the furnace be , and the current time be , calculate the waiting time, and the calculation expression is as follows: , where is the waiting time; Let the current position of each AGV , and the position of the target blanking point be , calculate the Euclidean distance, and the calculation expression is as follows: , where and are the current position coordinates of the th AGV forklift, and are the coordinates of the target blanking point, is the Euclidean distance between the th AGV and the target point; According to the remaining power , speed coefficient , load coefficient of each AGV, obtain the scheduling priority score, and the calculation expression is as follows: , where is the scheduling priority score of the th AGV, load coefficient, ; Select the AGV corresponding to the maximum among all idle AGVs to execute the current task, and the remaining vehicles enter the waiting queue.

[0012] Preferably, the AGV forklift is equipped with a dual visual recognition system, including a two-dimensional code recognition module and a lidar scanning module, which are used to accurately locate the tray position and the driving path; The QR code recognition system uses the on-board camera to scan the label on the bottom of the pallet to obtain the pallet number and material roll product information; the lidar module simultaneously scans the ground and obstacles to build a real-time environmental map; The vision system communicates with the AGV dispatching platform in real time, transmitting position data via the UDP protocol and refreshing it every 5 milliseconds to ensure optimal path selection. It automatically avoids obstacles and dynamically replans the path during driving to ensure that the pallet accurately reaches the target location.

[0013] Preferably, when the AGV forklift is transferring the film roll pallet to the curing furnace or buffer area, a path planning algorithm based on the fusion of A-path search and dynamic window method is used to pre-generate the optimal path before executing the task, and to perceive the operating status of other AGVs and environmental obstacles in real time during the transfer process to achieve collision avoidance and path replanning; During the route planning process, each driving route is equipped with a transfer segment number and a timestamp recording mechanism. The WMS system dynamically adjusts the target curing furnace entry point based on the film roll curing time window and the waste heat utilization rate in the furnace. If the current target furnace area is temporarily full, the AGV is instructed to enter the intermediate buffer area first, temporarily store it according to the preset FIFO rules, and regularly rearrange the transfer queue to ensure smooth logistics of the entire production line and no conflicts in tasks.

[0014] Preferably, after completing the film roll transfer task, the AGV forklift automatically drives to the empty pallet recovery area and performs the following steps: The pallet detection sensor identifies the stacking height of empty pallets. If the height exceeds the preset safety threshold, it automatically switches to the standby empty pallet stacking point; Empty pallets are stacked to a standard height using a built-in lifting module, with no more than 6 layers per stack; According to the instructions of the dispatching system, transport to the entrance of the disassembly machine.

[0015] In the above technical solution, the technical effects and advantages provided by the present invention are: The present invention achieves high real-time and low-latency communication between the truss robot unloading control system and the AGV scheduling system by constructing a unified central control synchronization mechanism or high-frequency signal bus, breaking through the bottleneck problems such as network delay and instruction drift commonly seen in existing multi-system collaboration. The signal after each unloading action is completed can be received and responded to immediately by the AGV system at the millisecond level, avoiding a series of chain reactions such as pallet accumulation, task misordering, and transfer delays, greatly improving the stability and synchronization accuracy of the entire production line. This beneficial effect ensures the logical closed-loop execution of the automated process and is the key foundation for opening up the full-process control chain of "unloading-transfer-maturation".

[0016] The present invention introduces a task status feedback, anomaly detection, and scheduling rollback mechanism, constructs a complete control closed-loop, can identify the problem source in real time when the task is interrupted, instructions are lost, or the AGV scheduling fails, and automatically call the spare AGV resources to restart the task, or roll back to the previous successful node for rescheduling when necessary. This mechanism effectively avoids system paralysis and production stagnation caused by single-point failures, and improves the robustness and stability of the entire system. In a continuous and high-tempo production environment, this beneficial effect ensures seamless connection between devices, and improves the overall line operation efficiency and risk resistance ability.

[0017] By introducing an AGV priority scoring model and a predictive control algorithm, the present invention completes data collection, real-time calculation, and path planning before task scheduling, effectively integrates multi-dimensional information such as film roll weight, transfer distance, vehicle status, and task timing, and combines historical task data to predict the system delay trend, ensuring that each AGV call is based on the optimal resource allocation result. This strategy not only improves the execution efficiency of a single task, but also avoids problems such as AGV resource idling, congestion, and scheduling conflicts, making the entire blanking and transfer process more intelligent and adaptive. This beneficial effect significantly improves the flexible adjustment ability of the production tempo and the comprehensive utilization rate of system resources. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required in the embodiments. Obviously, the drawings described below are only some embodiments recorded in the present invention, and those of ordinary skill in the art can also obtain other drawings based on these drawings.

[0019] Figure 1 It is a method flow chart of the automatic blanking and transfer method for polyester PET film rolls of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0020] Now, the exemplary embodiments will be described more fully with reference to the accompanying drawings. However, the exemplary embodiments can be implemented in various forms and should not be construed as limited to the examples set forth herein; rather, these exemplary embodiments are provided so that this disclosure will be more comprehensive and complete, and will fully convey the concept of the exemplary embodiments to those skilled in the art.

[0021] The present invention provides an automatic blanking and transfer method for polyester PET film rolls as Figure 1 shown, including the following steps: S1. Use the gantry robot to receive the blanking instruction from the production management system, and after a roll of polyester PET film roll is produced by the film laminating machine, the gantry robot takes out the film roll from the winding station and places it on a special tray provided with a positioning and limiting structure; The gantry robot adopts a three-axis linkage structure, corresponding to Axis (cross - movement), Axis (longitudinal movement) and Axis (lifting) directions, and integrate a set of variable - position handling fixtures. The fixtures have dual functions: one is to hook the core shaft of the film roll through a rotating hook structure to achieve heavy - load lifting; the other is to grasp the core shaft through a parallel - jaw structure to complete the extraction and insertion actions; Whenever the robot performs the pre - blanking action, its control system automatically adjusts the fixture spacing according to the film roll diameter and core shaft length data issued by the MES to ensure handling stability and blanking accuracy.

[0022] To improve the blanking efficiency, the truss robot is equipped with a status feedback module. Each action node is calibrated through a position encoder and is fed back to the main control system in real - time to ensure that the AGV scheduling system can synchronously start the subsequent process.

[0023] The tray is provided with a bidirectional limit groove structure and adjustable wedge - shaped limit blocks. Each tray surface is preset with three symmetrically distributed limit tracks for stacking three film rolls in a "pin" shape; Each wedge - shaped limit block is connected to the track through a sliding buckle device, and the sliding distance is accurately marked by a coding scale at the bottom of the tray; When the truss robot performs the stacking action, it automatically calls the limit block displacement program according to the film roll specifications, so that both ends of each film roll are stably supported by the limit blocks; The limit structure is also equipped with an anti - seismic buffer cushion layer, which can effectively absorb the micro - vibrations generated during transportation, prevent the film roll from shifting or tipping over, and thus ensure the stacking safety and transfer stability.

[0024] S2. While the truss robot completes the blanking action, the blanking control system generates a blanking - completed signal, and this signal is sent to the AGV scheduling system through an intermediate communication interface; A multi - system synchronous control logic module is set in the control system. Its core is the timestamp synchronization algorithm. Each blanking event records an accurate timestamp after the truss robot completes the last action node , the response time of the AGV scheduling system after receiving the signal is denoted as , if is the time difference, the control system will trigger a synchronous exception handling mechanism, automatically start a standby AGV or resend the instruction to avoid task backlog.

[0025] All timestamp information is recorded in the log for subsequent traceability and system optimization, fundamentally improving the stability and response consistency of the system.

[0026] By monitoring and judging whether it exceeds , the system can automatically detect potential communication problems or control delays, and promptly start the backup instruction resending mechanism or standby AGV scheduling mechanism to ensure the real-time and reliability of the entire automated transfer process.

[0027] In order to ensure the system scheduling stability and response time accuracy, a scheduling response correction mechanism based on PID+ prediction algorithm is added to the control system. The specific steps are as follows: Set the target value of task signal delay , the current measured system delay is , define the error term, and the calculation expression is as follows: , where is the error term, which represents the deviation between the current actual delay and the target delay. A positive value indicates that the delay is longer than expected, and a negative value indicates that the reaction is too fast (which can be used to judge overcompensation); Set the scale factor , integral coefficient , differential coefficient , calculate the adjustment parameters, the calculation expression is as follows: , where Is the proportional coefficient, which is used to determine the direct proportional relationship of the error term in the control output. is the integral coefficient, which is used to accumulate the trend of error over time and eliminate static error. Is the differential coefficient, which is sensitive to the rate of change of the error and is used to predict trends in advance. is the PID controller at time Given the adjustment signal, control the signal adjustment amount, comprehensively consider the current error, historical error accumulation and error change trend, Is an imaginary time variable, representing the time from the start time 0 to the moment A scan variable of At every point in time The systematic error on time At time , the difference between the system target value and the actual value, is a small time increment, which is a time variable An infinitesimal increment of , used to describe a very short period of time The tiny "area" accumulated; The time series prediction model AR(1) is used to estimate the delay of the next cycle. The delay calculation formula is as follows: , where It is the predicted delay of the next cycle. Based on the historical delay sequence, it estimates the possible communication delay of the next task cycle. It is the autocorrelation coefficient of delay, which reflects the influence of current delay on future delay. When it is close to 1, the system inertia is large. The value range is 0-1. is the model offset correction amount, which is used to compensate for the influences of non-linear errors, network fluctuations, system loads, etc.; Adjust the thread scheduling priority of the signal relay server. The formula is as follows: , where in the formula, is the comprehensive index of the scheduling priority. The larger the value, the closer the current system state is to the ideal state; When , is the preset tolerance threshold, which triggers the main control system to switch to the standby relay server to ensure the continuity of instruction transmission and the real-time response.

[0028] S3. After the AGV scheduling system receives the signal indicating that the material unloading is completed, it calls the preset path rule and the transfer sequence priority strategy, selects the corresponding idle AGV forklift from the AGV task pool, and allocates it to execute the current transfer task; During the execution of the material unloading and transfer sequence task, the AGV scheduling priority is optimized in real time. The specific steps are as follows: Let the weight of the film roll be , and the weight of the tray be , calculate the total load. The calculation expression is as follows: , where in the formula, is the total load weight, which represents the total weight that needs to be borne in the actual handling task of the AGV; Let the estimated time for the film roll to come out of the furnace be , and the current time be , calculate the waiting time. The calculation expression is as follows: , where in the formula, is the waiting time, which represents how much remaining time there is for the current task from its ideal time to come out of the furnace. If is smaller, it means the task urgency is higher, and it is necessary to prioritize scheduling how much remaining time there is for the previous task from its ideal time to come out of the furnace; Let the current position of each AGV be , and the target material unloading point position be , calculate the Euclidean distance. The calculation expression is as follows: , where in the formula, and are the current position coordinates of the th AGV forklift, which represent the absolute position of each AGV in the factory map at present, and are the target material unloading point coordinates, which represent the position coordinates of the tray where the current film roll is located, is the The Euclidean distance between an AGV and the target point represents the straight-line distance in space between the AGV and the target blanking point. The smaller the value, the closer the AGV is to the task starting point; According to the remaining power of each AGV , speed coefficient , load coefficient , the scheduling priority score is obtained, and the calculation formula is as follows: , where, is the th AGV's scheduling priority score. The larger the score value, the higher the priority. The scheduling system will select the AGV with the largest to execute the current transfer task. The load coefficient, , represents the load ratio that can be supported by the unit remaining power. The higher the value, the worse the current power support ability, and the scheduling priority should be reduced; Among all idle AGVs, select the one with the largest to execute the current task, and the remaining vehicles enter the waiting queue.

[0029] S4. The AGV forklift travels to the blanking station according to the specified path navigation system. After automatically identifying the pallet barcode and confirming the load information, it loads the pallet together with the film roll onto the vehicle body; The AGV forklift is equipped with a dual vision recognition system, including a QR code recognition module and a lidar scanning module, which are used to accurately locate the pallet position and the driving path; The QR code recognition system scans the label at the bottom of the pallet through the on-vehicle camera to obtain the pallet number and the product information of the film roll; the lidar module synchronously scans the ground and obstacles to construct an instant environment map; The vision system communicates with the AGV scheduling platform in real time, transmits the position data through the UDP protocol, and refreshes it every 5 milliseconds to ensure the optimal path selection. During the driving process, it automatically avoids obstacles and dynamically re-plans the path to ensure that the pallet accurately reaches the target position.

[0030] S5. According to the task instructions in the MES system, the AGV forklift accurately transfers the film roll pallet to the specified curing furnace entrance or the temporary buffer area, and the task execution status is uploaded to the warehouse management system in real time; During the process of the AGV forklift transferring the film roll pallet to the curing furnace or the buffer area, it adopts a path planning algorithm that combines the A* path search and the dynamic window approach (DWA). It pre-generates the optimal path before executing the task, and in the process of transfer, it real-time senses the running status of other AGVs and environmental obstacles to achieve collision avoidance and path re-planning; During the path planning process, each driving path is equipped with a transfer section number and an in-section timestamp recording mechanism. The WMS system dynamically adjusts the target curing furnace entry point according to the film roll's waiting-to-cure time window and the waste heat utilization rate in the furnace. If the current target furnace area is temporarily full, the AGV is instructed to enter the intermediate buffer area first, and is temporarily stored according to the preset FIFO rule, and the transfer queue is rearranged regularly to ensure the smooth logistics and conflict-free tasks of the entire production line.

[0031] This mechanism effectively solves the path interference and target point competition problems under multi-vehicle scheduling, and improves the overall stability of the system and the resource utilization efficiency.

[0032] S6. After the AGV completes the transfer task, the truss robot control system resets and enters the standby state. After receiving the next film roll blanking instruction, repeat S1 to S5 to ensure operation under closed-loop logic control and avoid scheduling conflicts. After the AGV forklift completes the film roll transfer task, it automatically drives to the empty pallet recycling area and performs the following steps: First, identify the stacking height of the empty pallets through the pallet detection sensor. If the height exceeds the preset safety threshold, automatically switch to the standby empty pallet stacking point; then stack the empty pallets to the standard height through the built-in lifting module, with no more than 6 layers per stack; finally, transport to the entrance of the pallet dismantling machine according to the instruction of the scheduling system.

[0033] This process is completely unattended, and all pallet transfer data will be synchronously uploaded to the WMS warehouse management system to form a complete pallet circulation traceability record, improving the system visualization and asset supervision capabilities.

[0034] Embodiment 1: During the production process of polyester PET film rolls, the film rolls are heavy, large in size and have high requirements for transfer stability after leaving the film coating machine. Therefore, during the automated blanking and transfer process, the coordinated scheduling between the truss robot and the AGV system becomes a key link for the smooth operation of the system. To solve the possible problems such as communication delay, instruction loss, and scheduling disorder between the truss robot and the AGV, this embodiment proposes a control architecture based on the central control synchronous signal bus, and realizes the real-time sharing and distribution of key control information through a high-speed industrial bus system.

[0035] This system integrates the truss robot blanking controller, the AGV scheduling terminal, the MES execution platform and the WMS warehouse system into a set of bus structures. The selected bus is the industrial Ethernet Profinet or EtherCAT system, which has millisecond-level data response capabilities and high anti-interference ability, and can ensure error-free data synchronization in a high-speed and complex industrial environment. The system sets up a central control management unit as the main node of signal scheduling, and all control terminals are connected to this central control unit in the form of slave stations.

[0036] During implementation, after the gantry robot completes the final action of removing the film roll and placing it on the pallet, it automatically generates an "action completed" signal through its built-in sensor. This signal is not transmitted over the standard TCP / IP network, but directly transmitted to the bus master via a hardware interrupt. Upon receiving this signal, the master immediately triggers the AGV dispatch response process, issuing the transfer task to the highest-priority idle AGV unit.

[0037] The greatest advantage of this architecture lies in its concise command chain, fast response, and unique transmission path. In traditional hierarchical network structures, gantry robots must upload information via local controllers to a central control platform, which then parses and distributes tasks to AGVs. This long path and multiple processing steps can easily cause information delays. In this approach, all nodes are arranged in parallel within a bus structure, and signal processing has real-time interrupt priority. The system can complete the generation and response of task instructions within tens of milliseconds, greatly reducing the error rate.

[0038] During each round of task scheduling, the central control management unit records each instruction's timestamp, signal content, execution unit number, response latency, and other data, forming a complete task flow log. This log can be used for later fault tracing and performance evaluation, and can be used to adjust priority parameters and optimize control strategies based on actual response characteristics during system upgrades.

[0039] In addition, the solution also incorporates a redundancy mechanism, namely, each AGV controller is equipped with a cache register. In the event of short-term bus congestion or controller failure, instructions can be retained locally and wait for self-check recovery in the next communication cycle, effectively enhancing the stability and robustness of the system.

[0040] Through the application of this embodiment, the entire polyester PET film roll unloading and sequencing process can achieve millisecond-level linkage, completely eliminating the risk of chain break between devices where "the action is completed but no one takes over", achieving true automated seamless connection, and effectively supporting large-scale, high-beat continuous production operations.

[0041] Implementation 2: In actual industrial applications, control structures that rely solely on one-time dispatch communications are highly susceptible to incidental factors, leading to control anomalies or scheduling losses. Therefore, this implementation, focusing on system stability and robustness, constructs a closed-loop dispatch control system with task self-detection, state feedback, and anomaly correction capabilities. This system manages the collaborative execution of gantry robots and AGVs in the automated unloading and reordering process for polyester (PET) film rolls.

[0042] In this architecture, each robotic blanking action does not simply end with the mechanical placement action itself, but is accompanied by a complete closed-loop cycle of "execution confirmation - scheduling response - task completion". After the truss robot completes an action, it not only sends a "completed" instruction, but also generates a unique task identification code in its local control unit, and simultaneously starts a listening mode waiting for the AGV response. If the AGV status receipt (such as start, in place, successful pallet identification, etc.) is not received within the set listening time window, the system will automatically trigger the task exception handling logic.

[0043] The exception handling mechanism includes the following items: First, the system marks the status of the current task as "delayed response" and resends the scheduling instruction once; Second, if there is still no response after resending, it will immediately schedule alternative AGV resources and set the original AGV allocation instruction as "invalid recovery"; Third, if the transfer fails twice in a row, the truss robot system will pause the subsequent stacking to prevent pallet accumulation overflow and notify the operation management system for manual confirmation and handling.

[0044] In addition, the system also has a task status rollback mechanism. When the AGV completes the handling task, it will feedback "pallet out of warehouse confirmation" to the control platform, and this feedback will be used to verify whether the previous task is closed-loop complete. If it is found that there is a missing intermediate state or a task status jump, the task chain will be reconstructed, and the current process will be logged and performance evaluated.

[0045] To improve the overall fault tolerance, the system also designs a scheduling fuzzy state recognition module. If problems such as path deviation, low battery, and sensor failure occur during the task execution of the AGV device, the system can identify and interrupt the task for task reconstruction. At the same time, each AGV terminal supports a task lock mechanism to ensure task uniqueness and avoid scheduling duplication and logic confusion.

[0046] The closed-loop control system constructed in this way not only ensures the precise docking of the robotic blanking and AGV transfer actions, but also significantly improves the stable operation ability and fault self-healing ability of the system through the whole-process status monitoring and exception management logic, meeting the extremely high requirements for reliability in high-intensity industrial scenarios.

[0047] Embodiment 3: In the automated production process of polyester PET film rolls, especially in the case of the coordinated operation of multiple coating machines, truss robots, and AGVs, simply relying on fixed scheduling rules and static path allocation is difficult to adapt to the complex scheduling requirements of high speed, flexibility, and multi-process intersection. To solve the problems of possible instruction mismatch, response delay, or resource mismatch between the truss robot and the AGV during the actual task operation, this embodiment proposes a comprehensive scheduling optimization method that combines a task priority scoring system and a predictive path control algorithm.

[0048] The core of this method is to introduce an "intelligent dynamic scheduling engine", which is integrated into the system's AGV scheduling platform. It collects multi-dimensional data in real time, including truss robot unloading instructions, pallet status, film roll product parameters, current AGV operation status, remaining power, space occupancy, and task priority set in the production management system. Based on this, it makes a comprehensive scoring judgment and dynamically allocates the most suitable AGV to perform unloading and transfer tasks.

[0049] When the truss robot completes the film roll unloading action, the system will immediately generate a transfer task information, which includes key fields such as the film roll number, pallet number, starting position, target station, and maximum response time. After receiving the task, the scheduling engine will capture information on all currently idle or semi-idle AGV resources within milliseconds, including their current location, the status of the task being executed, the estimated completion time, the battery status, the number of tasks executed, etc. The system comprehensively ranks each AGV through a set multi-dimensional scoring formula to ensure that the equipment most suitable for the current task is dispatched first, rather than being allocated by fixed number or path, thereby effectively reducing resource waste and unnecessary waiting time.

[0050] In addition to a static scoring system, the system also integrates a predictive control model. This model uses historical route records, current equipment distribution, and task backlog to predict traffic density and queue lengths in major corridors and intersections within the next 1-2 minutes. If the highest-scoring AGV is detected about to enter a predicted high-latency area, the scheduling engine immediately skips it and selects the suboptimal path with the lowest scheduling cost, thus avoiding potential system stalls or path conflicts. This highly forward-looking mechanism ensures continuous task execution and system smoothness.

[0051] Furthermore, the system introduces a "task buffer pool" mechanism. Instead of immediately dispatching unloading signals from the gantry robot, it allows multiple tasks to accumulate over a certain period of time, then centrally schedules them based on the AGV's movement trends. For example, if an AGV is near a workstation and about to complete a task, the system can determine whether its path can also carry out a newly generated task in the vicinity. If so, it automatically incorporates this task into its path planning, forming a "multi-point collection, one-line delivery" path aggregation strategy. This significantly increases the output value of each AGV task execution and reduces idle and ineffective operations.

[0052] To support these intelligent scheduling capabilities, the system employs a task status awareness mechanism. Each dispatch execution records parameters such as task response time, actual route duration, wait time, and delays. All this data is analyzed and fed back to the scheduling scoring system for parameter fine-tuning, enabling model self-learning and continuous optimization of scheduling strategies. For example, if an AGV's response time is repeatedly slow under high load, the system will automatically lower its priority in subsequent scoring, reducing the frequency of its task assignments and ensuring balanced scheduling across the entire system.

[0053] In terms of deployment, the scheduling engine supports standardized protocol communication with MES systems, WMS systems, AGV control systems, and truss robot control systems. Task exchange follows the REST API interface specification, and all instructions have execution logs and receipt mechanisms to ensure that the entire system scheduling process is controllable and traceable.

[0054] This implementation enables dynamic scheduling, efficient path selection, and adaptive resource allocation in complex task environments within the automated production of polyester (PET) film rolls. This solution not only resolves the command synchronization issue between gantry robots and AGVs, but also enables the system to maintain extremely high operational efficiency and scheduling reliability even in high-frequency operations, intensive tasks, and complex paths, providing strong support for flexible scheduling in large-scale automated factories.

[0055] The present invention achieves high real-time and low-latency communication between the truss robot unloading control system and the AGV scheduling system by constructing a unified central control synchronization mechanism or high-frequency signal bus, breaking through the bottleneck problems such as network delay and instruction drift commonly seen in existing multi-system collaboration. The signal after each unloading action is completed can be received and responded to immediately by the AGV system at the millisecond level, avoiding a series of chain reactions such as pallet accumulation, task misordering, and transfer delays, greatly improving the stability and synchronization accuracy of the entire production line. This beneficial effect ensures the logical closed-loop execution of the automated process and is the key foundation for opening up the full-process control chain of "unloading-transfer-maturation".

[0056] The present invention introduces task status feedback, anomaly detection, and scheduling rollback mechanisms, establishing a complete closed-loop control system. This system can immediately identify the source of problems when a task is interrupted, an instruction is lost, or AGV scheduling fails, and automatically call upon backup AGV resources to restart the task, or, if necessary, roll back to the previous successful node for rescheduling. This mechanism effectively avoids system paralysis and production stagnation caused by single-point failures, improving the robustness and stability of the entire system. In a continuous, high-paced production environment, this beneficial effect ensures seamless connectivity between devices, improving the overall operational efficiency and risk resistance of the entire line.

[0057] The present invention completes data collection, real-time calculation, and path planning before task scheduling by introducing an AGV priority scoring model and a predictive control algorithm, effectively integrating multi-dimensional information such as roll weight, transfer distance, vehicle status, and task timing, and predicting the system delay trend in combination with historical task data to ensure that each AGV call is based on the optimal resource allocation result. This strategy not only improves the execution efficiency of a single task but also avoids problems such as AGV resource idling, congestion, and scheduling conflicts, making the entire blanking and transfer process more intelligent and adaptive. This beneficial effect significantly improves the flexible adjustment ability of the production beat and the comprehensive utilization rate of system resources.

[0058] The above formulas are all dimensionless and take their numerical values for calculation. The formulas are obtained by collecting a large amount of data for software simulation to get a formula closest to the actual situation. The preset parameters in the formulas are set by those skilled in the art according to the actual situation.

[0059] Only some exemplary embodiments of the present invention have been described by way of illustration above. Undoubtedly, for those of ordinary skill in the art, the described embodiments can be modified in various different ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

[0060] It should be noted that in this text, if there are relational terms such as first and second, they are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "including a..." does not exclude the existence of additional identical elements in the process, method, article or device including the element.

[0061] It should be understood that in various embodiments of the present application, the magnitudes of the serial numbers of the above processes do not mean the order of execution is prior or subsequent. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation to the implementation process of the embodiments of the present application.

[0062] Those of ordinary skill in the art can realize that the units and algorithm steps of each example described in combination with the embodiments disclosed herein can be implemented by electronic hardware, or by a combination of computer software and electronic hardware. Whether these functions are executed in a hardware or software manner depends on the specific application and design constraints of the technical solution. Professional technicians can use different methods to implement the described functions for each specific application, but such implementation should not be considered to exceed the scope of this application.

[0063] Those skilled in the art can clearly understand that for the convenience and brevity of description, the specific working processes of the systems, devices, and units described above can refer to the corresponding processes in the foregoing method embodiments and will not be elaborated herein.

[0064] The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place, or may be distributed to multiple network units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0065] In addition, the functional units in each embodiment of this application can be integrated into one processing unit, or each unit can exist physically alone, or two or more units can be integrated into one unit.

[0066] As described above, the above is only the specific implementation manner of this application, but the protection scope of this application is not limited thereto. Any person skilled in the art can easily think of changes or substitutions within the technical scope disclosed in this application, and all should be covered by the protection scope of this application. Therefore, the protection scope of this application should be subject to the protection scope of the claims.

[0067] Only some exemplary embodiments of the present invention have been described above by way of illustration. Undoubtedly, for those of ordinary skill in the art, without departing from the spirit and scope of the present invention, the described embodiments can be modified in various different ways. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the protection scope of the claims of the present invention.

Claims

1. Automatic blanking and transfer method for polyester PET film rolls, characterized in that, It includes the following steps: S1. The truss robot receives the blanking instruction from the production management system. After a roll of polyester PET film is produced by the film laminating machine, the truss robot takes out the film roll from the winding station and places it on a special tray with a positioning and limiting structure; S2. While the truss robot completes the blanking action, the blanking control system generates a blanking completion signal, which is sent to the AGV scheduling system through the intermediate communication interface; S3. After receiving the blanking completion signal, the AGV scheduling system calls the preset path rule and the transfer sequence priority strategy, selects the corresponding idle AGV forklift from the AGV task pool, and assigns it to execute the current transfer task; S4. The AGV forklift travels to the blanking station according to the specified path navigation system. After automatically identifying the tray barcode and confirming the load information, it loads the tray together with the film roll onto the vehicle body; S5. The AGV forklift accurately transfers the film roll tray to the specified curing furnace entrance or the temporary buffer area according to the task instruction in the MES system, and the task execution status is uploaded to the warehouse management system in real time; S6. After the AGV completes the transfer task, the control system of the truss robot resets and enters the standby state. After receiving the blanking instruction for the next roll of film, it repeats S1 to S5 to ensure operation under closed-loop logic control and avoid scheduling conflicts.

2. The automatic blanking and transfer method of the polyester PET film roll according to claim 1, characterized in that, The truss robot adopts a three-axis linkage structure, corresponding to axis, axis and axis directions respectively, and integrates a set of variable-position handling fixtures. The fixtures have dual functions: one is to hook the core shaft of the film roll through a rotating hook structure to achieve heavy-load lifting; the other is to grab the core shaft through a parallel jaw structure to complete the extraction and insertion actions. Whenever the robot performs the pre-blanking action, its control system automatically adjusts the fixture spacing according to the film roll diameter and mandrel length data issued by the MES to ensure handling stability and blanking accuracy.

3. The automatic blanking and transfer method of the polyester PET film roll according to claim 1, characterized in that, The tray is provided with a bidirectional limiting groove structure and an adjustable wedge-shaped limiting block. Each tray surface is preset with three symmetrically distributed limiting tracks for stacking three rolls of film in a "pin" shape; Each wedge-shaped limiting block is connected to the track through a sliding buckle device, and the sliding distance is accurately marked by the coding scale at the bottom of the tray; When the truss robot performs the stacking action, it automatically calls the limiting block displacement program according to the film roll specifications, so that both ends of each film roll are stably supported by the limiting block; The limiting structure is also equipped with an anti-seismic cushion layer, which effectively absorbs the micro-vibrations generated during transportation, prevents the film roll from shifting or tipping over, and thus ensures the stacking safety and transfer stability.

4. The automatic blanking and transfer method of the polyester PET film roll according to claim 1, characterized in that, There is a multi-system synchronous control logic module in the control system. Its core is the timestamp synchronization algorithm. For each blanking event, an accurate timestamp will be recorded after the truss robot completes the last action node, and the response time of the AGV scheduling system after receiving the signal will be recorded. If the response time minus the time when the robot completes the last action node , the control system will trigger the synchronous exception handling mechanism, automatically start the standby AGV or resend the instruction to avoid task backlog.

5. The automatic blanking and transfer method of the polyester PET film roll according to claim 1, characterized in that, To ensure the system scheduling stability and response time accuracy, a scheduling response correction mechanism based on the PID+prediction algorithm is added to the control system, and the specific steps are as follows: Set the task signal delay target value and the measured system delay, and define the error term; Set the proportional coefficient, integral coefficient, and differential coefficient, and calculate the adjustment parameter; Use the time series prediction model to estimate the delay in the next cycle; Adjust the thread scheduling priority of the signal transfer server; When the comprehensive index of the scheduling priority is less than the preset tolerance threshold, trigger the main control system to switch to the standby relay server to ensure the continuity of instruction transmission and the real-time response; 6. The automatic blanking and transfer method of the polyester PET film roll according to claim 1, characterized in that, During the execution of the blanking transfer sequence task, the AGV scheduling priority is optimized in real time, and the specific steps are as follows: Calculate the total load; Based on the current position of each AGV and the position of the target blanking point, calculate the Euclidean distance; According to the remaining power, speed coefficient, and load coefficient of each AGV, obtain the scheduling priority score; Select the AGV with the highest scheduling priority score among all idle AGVs to execute the current task, and the remaining vehicles enter the waiting queue.

7. The automatic blanking and transfer method of the polyester PET film roll according to claim 1, characterized in that, The AGV forklift is equipped with a dual vision recognition system, including a QR code recognition module and a lidar scanning module, which are used to accurately locate the tray position and the driving path. The QR code recognition system scans the label at the bottom of the tray through an on-vehicle camera to obtain the tray number and the information of the coil product. The lidar module synchronously scans the ground and obstacles to construct an instant environmental map. The vision system communicates with the AGV scheduling platform in real time, transmits the position data through the UDP protocol, and refreshes it every 5 milliseconds to ensure the optimal path selection. During the driving process, it automatically avoids obstacles and dynamically re-plans the path to ensure that the tray accurately reaches the target position.

8. The automatic blanking and transfer method of the polyester PET film roll according to claim 1, characterized in that, When the AGV forklift transfers the film roll tray to the curing furnace or the buffer area, it adopts a path planning algorithm that combines the A path search and the dynamic window method. It pre-generates the optimal path before executing the task, and in real time senses the running status of other AGVs and environmental obstacles during the transfer process to achieve collision avoidance and path re-planning. During the path planning process, each driving path is equipped with a transfer section number and an in-section timestamp recording mechanism. The WMS system dynamically adjusts the entrance point of the target curing furnace according to the waiting time window of the film roll for curing and the waste heat utilization rate in the furnace. If the current target furnace area is temporarily full, the AGV is instructed to enter the intermediate buffer area first, store it temporarily according to the preset FIFO rule, and re-arrange the transfer queue regularly to ensure the smooth logistics of the entire production line and no conflict in tasks.

9. The automatic blanking and transfer method of the polyester PET film roll according to claim 1, characterized in that, After the AGV forklift completes the film roll transfer task, it automatically drives to the empty tray recycling area and performs the following steps: Identify the stacking height of the empty trays through the tray detection sensor. If the height exceeds the preset safety threshold, it automatically switches to the backup empty tray stacking point. Stack the empty trays to the standard height through the built-in lifting module, with no more than 6 layers per stack. Transport to the entrance of the pallet dismantling machine according to the instruction of the scheduling system.

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