Automatic section sorting method

Abstract

The application discloses a profile automatic sorting method, and belongs to the technical field of material sorting. The type and quantity of required profiles are extracted based on order information, a structured task queue is generated, and then the required profiles are grabbed to a rotating disc, and after the profile posture correction is completed on the rotating disc, the profiles are pushed to a main conveying belt; a detection area is arranged on the main conveying belt, and the cross-sectional shape, surface quality and pit depth of the profiles are intelligently detected in sequence; according to the detection result, three-level classification is performed: qualified products are transferred to a processing area; products to be processed are transferred to a repair area; and unqualified products are transferred to a waste area. According to the order information, the profile is intelligently sorted, qualified profiles required by the order are quickly screened out, and the profile sorting efficiency and the processing quality of order products can be effectively improved.

Description

Technical Field

[0001] This invention relates to the field of material sorting technology, specifically to an automatic sorting method and system for profiles. Background Technology

[0002] In modern industrial production, a large amount of profiles are used as raw materials for processing. Since the cut profiles need to be welded in subsequent processes, they must be sorted and arranged to facilitate the rapid execution of these processes. Traditional profile sorting mainly relies on manual visual inspection or simple sensor technology. Due to the volume and weight of the profiles, workers consume a significant amount of physical strength and time during sorting, posing safety hazards and easily causing scratches and bumps, thus affecting product quality. Furthermore, manual labor reduces the overall product flow speed in the workshop, leading to slower delivery times. Additionally, the need for large workshop spaces to accommodate manual picking results in a significant waste of workshop space. Summary of the Invention

[0003] The purpose of this invention is to propose an automatic profile sorting method, which generates a structured task queue based on order information, then uses a robotic arm to grab the profiles and transports them to the inspection area via a main conveyor belt for inspection, and sorts and places them based on the inspection results, thereby greatly improving the sorting efficiency and quality of profiles.

[0004] The technical solution adopted in this invention is: an automatic profile sorting method, comprising:

[0005] Step S1: Extract the type and quantity of the required profiles based on the order information, generate a structured task queue, and drive the gripping device to grip the corresponding profiles onto the rotating disk;

[0006] Step S2: The profile is calibrated using a rotating disc to ensure its axis aligns with the main conveyor belt's transport direction, then pushed onto the main conveyor belt. Step S3: A detection zone is set up on the main conveyor belt. Once the profile is conveyed to the detection zone, an intelligent detection system sequentially performs intelligent detection on the profile's cross-sectional shape, surface quality, and pit depth. The intelligent detection system includes:

[0007] (1) Cross-section shape detection module: The profile of the profile is measured in a non-contact manner using a 3D line laser profile measuring instrument. The measured profile is compared with the preset standard threshold, and the maximum deviation and average deviation are calculated.

[0008] (2) Surface quality inspection module: Identifies processing quality defects on the profile surface through a 3D vision sensor array and marks the defect distribution area;

[0009] (3) Dent Depth Detection Module: Uses a phase laser rangefinder to detect dents on the surface of the profile, calculates the maximum depth of the dent area and compares it with a preset standard threshold to determine whether it exceeds the allowable range;

[0010] Step S4: After the profiles complete intelligent inspection, perform three-level classification based on the inspection results;

[0011] Step S5: Repeat steps S2-S4 until the profile sorting task for a single order is completed;

[0012] Step S6: Sequentially execute the sorting task for the next order.

[0013] As a further improvement of the present invention, the logic for generating the structured task queue in step S1 includes:

[0014] Execute combined gripping commands on profiles with the same cross-section to reduce the idle travel time of the robotic arm;

[0015] When the stock of profiles is insufficient, a material shortage warning will be automatically triggered and the queue of uncompleted orders will be retained.

[0016] When an urgent order is placed, the queue order is dynamically adjusted based on the remaining capacity.

[0017] As a further improvement of the present invention, in step S1, the grasping device is a vision robotic arm, which is equipped with an electric suction cup and a vision positioning module. Based on the camera capturing the target profile, its position is determined, and the robotic arm is driven to grasp the target profile.

[0018] As a further improvement of the present invention, in step S1, a positioning sensor is provided on the edge of the rotating disk to detect the angular offset of the profile. The profile on the rotating disk is rotated to be consistent with the conveying direction of the main conveyor belt by a servo drive. The corrected profile is pushed onto the main conveyor belt by a pneumatic lifting mechanism.

[0019] As a further improvement of the present invention, in step S3, the 3D vision sensor group includes a structured light 3D camera and a pair of multispectral 3D cameras; wherein, the structured light 3D camera includes a split structured light projector and an industrial camera, the structured light projector is installed directly above the detection area, projecting vertically downwards to cover the entire detection area, and the multispectral 3D cameras are installed in pairs on both sides of the detection area, at the same height as the structured light camera and staggered to form multi-view coverage.

[0020] As a further improvement of the present invention, in step S4, the three-level classification is specifically as follows:

[0021] (1) Qualified products: The cross-sectional shape, surface quality and length of the profiles meet the order requirements and are transferred to the processing area;

[0022] (2) Products to be processed: The surface of the profile has processing quality defects, including the following situations:

[0023] If a defect is located in a part of the profile that needs to be processed but the depth of the defect does not exceed the processing allowance, it is moved to the processing area; if there are deep pits on the surface, the location of the pits is detected, and it is determined whether the remaining effective length meets the requirements of other profiles in the order. If it does, it is moved to the rework area.

[0024] (3) Non-conforming products: those with severe cross-section deformation, deep pits on the surface, and remaining effective length that does not meet the requirements of other profiles in the order, shall be transferred to the scrap area.

[0025] As a further improvement of the present invention, in step S4, the profile with deep pits on its surface is subjected to the following treatment:

[0026] (1) Scan the pit area with a phase laser rangefinder to obtain the axial position coordinates and remaining length of the pit;

[0027] (2) Based on the order information, retrieve the profile requirements that have not been sorted yet. If there is an order task for profiles with the same cross-section whose length is ≤ remaining length - processing allowance, mark the profile as repairable surplus material and transfer it to the rework area.

[0028] (3) In the rework area, the pitted section is cut off according to the size of the new target profile using a CNC cutting machine, and the qualified section is added back to the sorting queue.

[0029] As a further improvement of the present invention, in step S4, if three or more defective products are sorted out consecutively, the intelligent detection system automatically triggers an audible and visual alarm and suspends the sorting process.

[0030] Upload the test data of abnormal profiles to the cloud analysis platform to generate a defect cause report, and resume operation after manual confirmation.

[0031] Compared with existing technologies, this invention solves the technical problems of low sorting efficiency and low profile utilization caused by existing manual sorting methods. The specific technical effects are as follows:

[0032] (1) Based on the profile type and quantity requirement instructions extracted from the order information, the present invention arranges the sorting order of the required profiles through the grabbing logic of the structured queue. The sorting task is clear and can effectively improve the sorting efficiency of profiles.

[0033] (2) The present invention sets up a detection area on the main conveyor belt, integrates three modules: cross-sectional contour detection, defect identification and pit depth detection, and constructs a three-dimensional quality evaluation mechanism to improve the product processing accuracy.

[0034] (3) The present invention cuts the profile with surface defects but remaining effective length into qualified products of other required profiles in the order, so that the products to be processed follow the process of inspection-rework-resorting-reinspection, thereby improving the utilization rate of profiles;

[0035] (4) The present invention sets up a three-time consecutive non-conforming product sound and light alarm mechanism, which can achieve the triple benefits of early defect detection, reduced sorting system downtime and reduced manual maintenance costs, and significantly improve the efficiency of profile sorting. Attached Figure Description

[0036] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0037] Figure 1 This is a flowchart of the automatic sorting method of the present invention;

[0038] Figure 2 This is a schematic diagram of an intelligent detection system;

[0039] Figure 3 This is a schematic diagram of the workflow of the intelligent detection system;

[0040] Figure 4 This is a diagram illustrating a usage scenario of the automatic profile sorting method of the present invention.

[0041] In the diagram: 1-Vision robotic arm, 2-Profile storage bin, 3-Rotating disk, 4-Position sensor, 5-Pneumatic push rod mechanism, 6-Main conveyor belt, 7-Detection area, 8-Push rod mechanism, 9-Rework area, 10-Waiting-for-processing area, 11-Scrap area. Detailed Implementation

[0042] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the described embodiments of the present invention are within the scope of protection of the present invention.

[0043] like Figure 1 and Figure 4 As shown, an automatic profile sorting method of the present invention includes the following steps:

[0044] Step S1: Extract the type and quantity of the required profiles based on the order information, generate a structured task queue, and drive the vision robotic arm 1 to grab the corresponding profiles from the profile warehouse 2 onto the rotating disk 3.

[0045] The process of extracting the required profile type and quantity based on order information is performed according to the following steps:

[0046] 1. Create a Bill of Materials (BOM) for each product; the BOM is the basic document for breaking down profiles, which includes the profile specifications required for each product, such as length, cross-sectional dimensions, material, and quantity. Create a detailed BOM for each product, specifying the part number, name, specifications, and unit usage of the profile.

[0047] 2. Linking Orders with Bills of Materials (BOMs): Using the ERP / MRP system, bind the products in the order to the BOM, extract the specifications and required quantities of the profiles in the order, and finally generate a profile list. Based on the profile list, generate a structured task queue. Specifically, the logic for generating the structured task queue includes:

[0048] For profiles with the same cross-section, a merged grasping command is executed to reduce the idle travel time of the vision robotic arm 1; when the inventory of profiles is insufficient, a material shortage warning is automatically triggered and the queue of uncompleted orders is retained; when an urgent order is placed, the queue order is dynamically adjusted based on the remaining capacity. The grasping equipment performs the above structured tasks.

[0049] The gripping device operates based on the vision robotic arm 1. The robotic arm is equipped with an electric suction cup and a vision positioning module. It uses a camera to capture the target profile, determine its position, and drive the robotic arm to grip the target profile.

[0050] Step S2: After the vision robotic arm 1 grasps the target profile, it places it onto the rotating disk 3. The rotating disk 3 corrects the profile's posture, aligning its axis with the conveying direction of the main conveyor belt 6. Positioning sensors 4 are installed on the edge of the rotating disk 3 to detect the profile's angular offset. A servo drive rotates the profile on the rotating disk until it aligns with the conveying direction of the main conveyor belt. A pneumatic lifting mechanism 5 then pushes the corrected profile onto the main conveyor belt.

[0051] Step S3: A detection zone 7 is set up on the main conveyor belt 6. When the profile is conveyed to the detection zone 7, the cross-sectional shape, surface quality, and pit depth of the profile are intelligently detected sequentially by the intelligent detection system. Figure 2 and Figure 3 As shown, detection area 7 is equipped with the following three detection modules:

[0052] 1. Cross-sectional shape detection module: This module uses a 3D line laser profile measuring instrument to measure the profile of the target profile in a non-contact manner. The measured profile is compared with a preset standard threshold to calculate the maximum and average deviations. Specifically, after the profile enters the detection area, the conveying process stops and the 3D line laser profile measuring instrument is activated. It projects a line laser onto the profile surface, receives the reflected light, calculates the height difference, generates a high-density point cloud, acquires the cross-sectional profile image of the target profile, performs deviation analysis, and generates detection results in real time. Qualified products are transferred to the processing area to await the next process, while products with deformed cross-sectional profiles are marked as unqualified and transferred to the scrap area.

[0053] 2. Surface Quality Inspection Module: This module identifies processing quality defects on the profile surface using a 3D vision sensor group, which includes a structured light 3D camera and a multispectral 3D camera. When the profile enters the inspection area, the 3D vision sensor group activates image acquisition to capture multi-dimensional images of the profile surface, highlighting minute defects. By intelligently identifying processing quality defects such as scratches, indentations, and oxide spots, the module marks the defect locations and classifies them as repairable / unrepairable. This triggers the pneumatic pusher at the end of the main conveyor belt to divert the profile to the corresponding area.

[0054] 3. Dent Depth Detection Module: Using phase laser ranging to scan the surface of the profile, calculate the maximum depth of the dent area and compare it with the preset standard threshold. Based on the depth and location, it automatically determines "cut off the remaining material" or "scrap disposal", triggering the pneumatic push rod at the end of the main conveyor belt to divert the profile to the corresponding area.

[0055] Step S4: After the profile completes intelligent inspection, it continues to be transported, and a three-level classification is performed based on the inspection results.

[0056] 1. Qualified products---The cross-sectional shape, surface quality and length of the profiles all meet the order requirements, and are transferred to the processing area 10 by the push rod mechanism 8.

[0057] 2. The surface of the profile to be processed has processing quality defects, including the following:

[0058] (1) When the defect is in the part of the profile that needs to be processed but the depth of the defect does not exceed the processing allowance, it is moved to the processing area 10 by the push rod mechanism 8;

[0059] (2) If there are deep pits on the surface, the location of the pits is detected, and it is determined whether the remaining effective length meets the requirements of other profiles in the order. If it does, it is transferred to the rework area 9 through the push rod mechanism 8. Specifically, the pit area is scanned by a laser displacement sensor to obtain the axial position coordinates and remaining length of the pits; based on the order information, the current unsorted profile requirements are retrieved. If there is an order task with a length requirement ≤ remaining length - processing allowance (i.e., remaining effective length), the profile is marked as repairable surplus material and transferred to the rework area 9. In the rework area, the pitted section is cut off by a CNC cutting machine according to the size of the new target profile, and the qualified section is added back to the sorting queue.

[0060] 3. Non-conforming products---severely deformed cross-section, deep pits on the surface, and the remaining effective length does not meet the requirements of other profiles in the order, are transferred to scrap area 11.

[0061] Step S5: Repeat steps S2-S4 to complete the profile sorting task for a single order.

[0062] Step S6: Sequentially execute the sorting task for the next order.

[0063] This invention extracts the specifications and quantity of the required profiles based on order information, then generates a structured queue task, drives the gripping device to grab the target profiles onto the rotating disk, and pushes them onto the main conveyor belt after directional adjustment. An inspection area is set on the conveyor belt to inspect the cross-section, surface quality, and pit depth of the profiles, and sorts them into qualified products, products to be processed, and unqualified products, which can greatly improve the sorting efficiency of profiles and the processing efficiency and quality of products.

[0064] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited thereto. Various changes that can be made within the scope of knowledge possessed by those skilled in the art without departing from the spirit of the present invention are all within the protection scope of the claims of the present invention.

Claims

1. An automatic profile sorting method, characterized in that, include: Step S1: Extract the type and quantity of the required profiles based on the order information, generate a structured task queue, and drive the gripping device to grip the corresponding profiles onto the rotating disk; Step S2: Correct the posture of the profile by rotating the disc, so that the axis of the profile is aligned with the transport direction of the main conveyor belt, and then push the profile onto the main conveyor belt. Step S3: A detection zone is set up on the main conveyor belt. When the profile is conveyed to the detection zone, the cross-sectional shape, surface quality, and pit depth of the profile are intelligently detected sequentially by the intelligent detection system. The intelligent detection system includes: (1) Cross-section shape detection module: The profile of the profile is measured in a non-contact manner using a 3D line laser profile measuring instrument. The measured profile is compared with the preset standard threshold, and the maximum deviation and average deviation are calculated. (2) Surface quality inspection module: Identifies processing quality defects on the profile surface through a 3D vision sensor array and marks the defect distribution area; (3) Dent Depth Detection Module: The module uses a phase laser rangefinder to detect dents on the surface of the profile, calculates the maximum depth of the dent area and compares it with a preset standard threshold to determine whether it exceeds the allowable range; Step S4: After the profile completes intelligent inspection, a three-level classification is performed based on the inspection results; the three-level classification is as follows: (1) Qualified products: The cross-sectional shape, surface quality and length of the profiles meet the order requirements and are transferred to the processing area; (2) Products to be processed: The surface of the profile has processing quality defects, for the following situations: If a defect is located in a part of the profile that needs to be processed but the depth of the defect does not exceed the processing allowance, it is moved to the processing area; if there are deep pits on the surface, the location of the pits is detected, and it is determined whether the remaining effective length meets the requirements of other profiles in the order. If it does, it is moved to the rework area. (3) Non-conforming products: those with severely deformed cross sections, deep pits on the surface, and remaining effective lengths that do not meet the requirements of other profiles in the order shall be transferred to the scrap area; Step S5: Repeat steps S2-S4 until the profile sorting task for a single order is completed; Step S6: Sequentially execute the sorting task for the next order.

2. The automatic profile sorting method according to claim 1, characterized in that, The logic for generating the structured task queue in step S1 includes: Execute combined gripping commands on profiles with the same cross-section to reduce the idle travel time of the robotic arm; When the stock of profiles is insufficient, a material shortage warning will be automatically triggered and the queue of uncompleted orders will be retained. When an urgent order is placed, the queue order is dynamically adjusted based on the remaining capacity.

3. The automatic profile sorting method according to claim 1, characterized in that, In step S1, the grasping device is a vision robotic arm, which is equipped with an electric suction cup and a vision positioning module. Based on the camera capturing the target profile, its position is determined, and the robotic arm is driven to grasp the target profile.

4. The automatic profile sorting method according to claim 1, characterized in that, In step S1, a positioning sensor is provided on the edge of the rotating disk to detect the angular offset of the profile. The profile on the rotating disk is rotated to be consistent with the conveying direction of the main conveyor belt by a servo drive. The corrected profile is pushed onto the main conveyor belt by a pneumatic lifting mechanism.

5. The automatic profile sorting method according to claim 1, characterized in that, In step S3, the 3D vision sensor group includes a structured light 3D camera and a pair of multispectral 3D cameras. The structured light 3D camera includes a split structured light projector and an industrial camera. The structured light projector is installed directly above the detection area and projects vertically downwards to cover the entire detection area. The multispectral 3D cameras are installed in pairs on both sides of the detection area, at the same height as the structured light camera and staggered to form multi-view coverage.

6. The automatic profile sorting method according to claim 1, characterized in that, In step S4, the following treatment is performed on profiles with deep pits on their surface: (1) Scan the pit area with a phase laser rangefinder to obtain the axial position coordinates and remaining length of the pit; (2) Based on the order information, retrieve the profile requirements that have not been sorted yet. If there is an order task for profiles with the same cross-section whose length is ≤ remaining length - processing allowance, mark the profile as repairable surplus material and transfer it to the rework area. (3) In the rework area, the pitted section is cut off according to the size of the new target profile using a CNC cutting machine, and the qualified section is added back to the sorting queue.

7. The automatic profile sorting method according to claim 1, characterized in that, In step S4, if three or more defective products are sorted out consecutively, the intelligent detection system will automatically trigger an audible and visual alarm and suspend the sorting process. It will then upload the detection data of the abnormal profiles to the cloud analysis platform, generate a defect cause report, and resume operation after manual confirmation.

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