Express balance wheel sorting machine control method and device and sorting machine

Abstract

The invention relates to an express balance wheel sorting machine control method and device and a sorting machine, and aims to improve the cargo posture stability and transmission efficiency in the logistics sorting process. The method comprises the following steps: receiving goods sorting path information, and generating a synchronous control instruction including swing wheel disc angle deflection, goods linear speed and a four-wheel belt transmission mechanism; the deflection angle of each swing wheel disc is calculated in real time, and on the premise of ensuring stable conveying of goods and balanced stress of each roller, the optimal rotating speed of a driving wheel is dynamically solved by adopting a multi-target dynamic optimization model on the basis of transmission balance among the driving wheel, a tensioning wheel and a driven wheel, so that the vibration torque of each belt is minimum, and the transmission efficiency is maximized. The control device is composed of a path information receiving module, a control instruction generating module, a swing wheel disc angle control module, a linear speed control module and a shearing vibration control module, efficient, low-energy-consumption, cooperative and intelligent control and stable transmission of the multi-swing-wheel disc sorting mechanism in the sorting process are achieved, and the multi-swing-wheel disc sorting mechanism is suitable for a logistics automatic sorting system.

Description

Technical Field

[0001] The present disclosure belongs to the technical field of synchronous control of automatic sorting equipment, and particularly relates to a control method and device for an express pendulum wheel sorting machine and a sorting machine. Background Art

[0002] In modern express logistics sorting systems, efficient and accurate automatic parcel sorting is key to improving logistics efficiency, reducing labor costs, and reducing error rates. Existing automatic sorting equipment primarily includes belt sorters, cross-belt sorters, and oscillating wheel sorters. Oscillating wheel sorters, in particular, are widely used in small and medium-sized express delivery operations due to their compact structure, flexible steering, and wide range of applications.

[0003] Traditional pendulum sorting mechanisms often utilize a multi-wheel linkage system with fixed speeds or simple proportional control. This makes it difficult to perceive and optimize the dynamic state of goods during the sorting process in real time, resulting in difficulty in coordinating the force state, energy consumption, and vibration levels of each pendulum disc during the sorting process. In particular, in multi-wheel belt drive systems, due to the complex coupling relationship between the driving pulley, driven pulley, and tensioning pulley, shear elastic delays, slippage, and disturbances in the belt segments can cause localized vibrations, reduce transmission efficiency, and increase energy consumption, making it difficult to achieve optimal energy consumption and dynamic robust control of the sorting process.

[0004] Furthermore, few control strategies currently combine the sorting path, the deflection angle of the pendulum disc, the coordination of multiple belt pulleys, shear coupling dynamics, and multi-objective dynamic optimization to achieve real-time optimal scheduling of the driving pulley, tensioning pulley, and each driven pulley as the package passes through the sorting path. This, while ensuring sorting stability, further reduces local vibration and energy consumption, achieving high-efficiency, low-vibration operation of the system. Therefore, minimizing the shear coupling vibration of the transmission system and optimizing sorting energy consumption based on the complex dynamic characteristics of the multi-wheel belt drive of express pendulum sorters is a technical challenge that urgently needs to be overcome in the field of intelligent sorting equipment. Summary of the Invention

[0005] In response to the above-mentioned drawbacks, the present disclosure provides a control method and device for an express oscillating wheel sorting machine, as well as a sorting machine. This method solves the problem that existing express oscillating wheel sorting machines, during the multi-wheel belt coordinated transmission process, have difficulty balancing the dynamic stability of the sorting path, synchronous drive of the rollers, minimization of shear coupling vibration, and optimization of energy consumption. This method achieves efficient, low-vibration, and low-energy operation of the multi-wheel system during the sorting process.

[0006] According to a first aspect of the present disclosure, a control method for an express pendulum wheel sorting machine is provided, comprising the following steps:

[0007] The control device receives information data on the cargo sorting path;

[0008] generating control instructions for the cargo sorting path, the control instructions including an angular deflection control instruction for each pendulum wheel in the sorting path, a cargo transfer linear speed control instruction, and a second motor rotation speed control instruction for rotating four wheels in a belt transmission mechanism that drives each pendulum wheel;

[0009] Using the path data for the cargo sorting path, calculating the angular deflection angle of each of the plurality of pendulum wheels, adjusting the cargo sorting path and ensuring a stable cargo posture;

[0010] Based on the angle deflection control, generating synchronization control instructions for the four rollers on each pendulum wheel, the synchronization control instructions including transmission speed control of each roller to ensure that the force exerted by each roller on the cargo during cargo transportation remains balanced;

[0011] Under the transmission balance constraints between the driving wheel, tensioning wheel and each driven wheel, a multi-objective dynamic optimization function is constructed to solve the optimal real-time rotation speed of the driving wheel that minimizes the coupled vibration torque on each belt section. On the basis of ensuring the synchronous drive of the four transmission rollers of each pendulum wheel during the sorting process, the minimum shear vibration and maximum transmission efficiency of the four wheels in the belt transmission mechanism of each pendulum wheel are achieved.

[0012] In some embodiments, using the path data for the cargo sorting path to calculate the angular deflection angle of each of the plurality of pendulum wheels, adjusting the cargo sorting path and ensuring a stable cargo posture, includes:

[0013] A reference angle position of each pendulum disc is set in the mechanism coordinate system; a corresponding target deflection angle is calculated based on different pre-planned sorting routes; each first motor controlling the pendulum disc independently responds to a control instruction and adjusts the corresponding pendulum disc to the target deflection angle based on feedback from an angle sensor.

[0014] In some embodiments, each of the first motors controlling the balance wheel independently responds to a control instruction and adjusts the corresponding balance wheel to the target deflection angle according to feedback from an angle sensor, including:

[0015] According to the real-time deflection angle of each pendulum wheel, the cargo loading area and cargo unloading area of ​​each pendulum wheel and the real-time location are determined;

[0016] Determining the friction torque compensation amount for each pendulum disc's real-time deflection angle within a target deflection angle range;

[0017] Calculating the first motor driving torque required for each balance wheel;

[0018] Determine the optimal real-time deflection angle of the pendulum wheel under the lowest energy consumption of the first motor during a sorting cycle in which a commodity is sorted.

[0019] In some embodiments, generating a synchronous control instruction for the optimal real-time transmission linear speed of the cargo based on the angle deflection control while ensuring that the force exerted on the cargo by each roller during cargo transportation is balanced includes:

[0020] Based on the real-time deflection angle of the first motor at the lowest energy consumption during a sorting cycle of a product, the real-time kinetic energy of the product and the normal force of the rollers on each pendulum disc are calculated to analyze the force conditions of the product during transportation;

[0021] Establish a real-time dynamic equation for cargo movement. By integrating the normal force and friction force on each pendulum disc, the force and acceleration changes on the cargo are determined to dynamically control the cargo transportation speed.

[0022] Construct a torque balance equation for the cargo on each pendulum disc. By analyzing the friction torque and the balance torque, determine the torque distribution during the roller transmission process, which is used to control the stability of the pendulum disc during rotation.

[0023] The Pontryagin maximum method is applied to solve the optimal real-time linear velocity of the goods in the transmission path through the pendulum disk with the constructed Hamiltonian as the optimization objective, so as to minimize energy consumption.

[0024] In some embodiments, under the transmission balance constraint between the driving pulley, the tensioning pulley, and each driven pulley, a multi-objective dynamic optimization function is constructed to solve the optimal real-time rotation speed of the driving pulley that minimizes the coupled vibration torque on each belt section, including:

[0025] Based on the acquired real-time rotation angle of each wheel in the belt transmission mechanism, the wrap angle parameters of each wheel and the disturbance angular frequency of the transmission system, the instantaneous motion state of the belt and each wheel is analyzed to achieve real-time perception of the disturbance working condition of the transmission system of each pendulum wheel;

[0026] Establish the belt stable transmission balance equation of the driving pulley, tensioning pulley and driven pulley to dynamically limit the energy and speed transfer between each wheel of the system and realize the modeling of the multi-wheel coordinated transmission relationship;

[0027] Based on the elastic response and slip characteristics of the shear layer of the belt segment, a multi-objective dynamic optimization model is constructed. The minimization of the total shear torque of each belt segment is optimized to optimize the driving force and speed distribution of the driving wheel. Ultimately, the optimal real-time rotational angular velocity control command of the driving wheel is obtained to minimize the overall energy consumption and vibration.

[0028] In some embodiments, establishing the belt stable transmission balance equation of the driving pulley, the tensioning pulley and the driven pulley includes determining the tension stiffness of multiple belt segments between the pulleys, the stiffness of the tensioning pulley and the damping stiffness of the driving pulley.

[0029] In some embodiments, the process of constructing the multi-objective dynamic optimization model further includes determining the shear layer equivalent stiffness of each belt segment.

[0030] According to a second aspect of the present disclosure, a control device for an express pendulum wheel sorting machine is provided, comprising:

[0031] A path information receiving module is configured to control the device to receive information data on the cargo sorting path;

[0032] a control instruction generation module configured to generate control instructions for the cargo sorting path, the control instructions including an angular deflection control instruction for each pendulum wheel in the sorting path and a second motor rotation speed control instruction for rotating four wheels in a belt transmission mechanism that drives each pendulum wheel;

[0033] a pendulum wheel angle control module, configured to calculate the angular deflection angle of each of the plurality of pendulum wheels, adjust the sorting path of the goods and ensure the stability of the goods;

[0034] The cargo transport linear speed control module is configured to generate a synchronous control instruction for the optimal real-time transmission linear speed of the cargo based on the angle deflection control, while ensuring that the force exerted on the cargo by each roller during the cargo transportation process is balanced;

[0035] The shear vibration control module is configured to construct a multi-objective dynamic optimization function under the transmission balance constraints between the driving wheel, the tensioning wheel and each driven wheel, and solve the optimal real-time rotation speed of the driving wheel that minimizes the coupled vibration torque on each belt section, thereby achieving minimum shear vibration and maximum transmission efficiency for the four wheels in the belt transmission mechanism of each pendulum wheel.

[0036] According to a third aspect of the present disclosure, a courier balance wheel sorting machine is provided, comprising a control device using the method described above, and further comprising a plurality of balance wheel mechanisms, each of the balance wheel mechanisms comprising a balance wheel disc, four rollers disposed on the balance wheel disc, a tensioning wheel, a driving wheel, a first motor, a second motor, and a transmission belt, wherein the four rollers disposed on the balance wheel disc comprise a first roller, a second roller, a third roller, and a fourth roller; the driving wheel, the tensioning wheel, the second roller, the fourth roller, and the transmission belt constitute a belt transmission mechanism;

[0037] The first motor drives each pendulum wheel to deflect on the cargo transfer plane, and the second motor drives the driving wheel to rotate, and then drives the four rollers to rotate through the transmission belt.

[0038] It should be understood that the contents described in this section are not intended to identify the key or important features of the embodiments of the present disclosure, nor are they intended to limit the scope of the present disclosure. Other features of the present disclosure will become readily understood through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The above and other features, advantages and aspects of the embodiments of the present disclosure will become more apparent with reference to the following detailed description in conjunction with the accompanying drawings. In the accompanying drawings, the same or similar reference numerals represent the same or similar elements.

[0040] Figure 1 A schematic diagram of a control device for implementing a control method for an express pendulum wheel sorting machine according to an embodiment of the present disclosure is shown.

[0041] Figure 2 A flow chart of a control method for an express pendulum wheel sorting machine according to an embodiment of the present disclosure is shown.

[0042] Figure 3 A flow chart of a control method 300 for an express pendulum wheel sorting machine according to an embodiment of the present disclosure is shown.

[0043] Figure 4 The figure shows the change of friction index compensation item when sorting goods weighing less than 5kg.

[0044] Figure 5 The figure shows the changes in the friction index compensation item when sorting goods weighing 5kg-20kg.

[0045] Figure 6 The figure shows the changes in the friction index compensation item when sorting goods weighing 20kg-30kg.

[0046] Figure 7 The figure shows the change of the driving torque Mt of the first motor during the sorting process of goods in different weight ranges.

[0047] Figure 8 A flow chart of a control method 400 of an express pendulum wheel sorting machine according to an embodiment of the present disclosure is shown.

[0048] Figure 9 The figures show the comparison between the measured values, expected values ​​and the expected values ​​of Comparative Example 1 for cargoes in different weight ranges under exponential acceleration conditions of the disclosed method.

[0049] Figure 10 The figure shows the comparison between the measured values, expected values ​​and the expected values ​​of comparative example 1 for cargoes of different weight ranges under uniform acceleration of the method disclosed herein.

[0050] Figure 11A flow chart of a control method 500 of an express pendulum wheel sorting machine according to an embodiment of the present disclosure is shown.

[0051] Figure 12 A schematic structural diagram of an express pendulum wheel sorting machine controlled by the control device 110 of the present disclosure is shown.

[0052] Figure 13 The top and side views of the express balance wheel sorting machine are shown.

[0053] Figure 14 The specific structure of the belt transmission mechanism and the four rollers in the balance wheel disc in the express balance wheel sorting machine is shown.

[0054] Figure 15 The specific structure of the belt transmission mechanism and the four rollers in the balance wheel disc in the express balance wheel sorting machine is shown from another perspective.

[0055] Figure 16 The specific positions of the belt segments of the belt transmission mechanism of the method disclosed in the present invention are shown.

[0056] Figure 17 The figure shows the lateral disturbance amplitude caused by the optimal rotational angular velocity change of the driving wheel obtained by the method of the present disclosure.

[0057] Figure 18 The longitudinal disturbance amplitude caused by the optimal rotational angular velocity change of the driving wheel optimized by the method disclosed in the present invention is shown. DETAILED DESCRIPTION

[0058] The following description of exemplary embodiments of the present disclosure is made in conjunction with the accompanying drawings, including various details of the embodiments of the present disclosure to facilitate understanding. These details should be considered as merely exemplary. Therefore, those skilled in the art will recognize that various changes and modifications may be made to the embodiments described herein without departing from the scope and spirit of the present disclosure. Similarly, for the sake of clarity and conciseness, descriptions of well-known functions and structures are omitted in the following description.

[0059] As used herein, the term "including" and its variations represent open inclusion, i.e., "including but not limited to." Unless otherwise stated, the term "or" means "and / or." The term "based on" means "based at least in part on." The terms "an example embodiment" and "an embodiment" mean "at least one example embodiment." The term "another embodiment" means "at least one additional embodiment." The terms "first," "second," etc. may refer to different or the same objects. Other explicit and implicit definitions may also be included below.

[0060] As described above, the traditional control method for the pendulum wheel sorter is unable to combine the sorting path, the pendulum wheel deflection angle, the coordination of multiple belt pulleys, the shear coupling dynamics, and multi-objective dynamic optimization to achieve real-time optimal scheduling of the driving wheel, tensioning wheel, and each driven wheel as the package passes through the sorting path.

[0061] In order to at least partially solve one or more of the above problems and other potential problems, the exemplary embodiments of the present disclosure provide a control method for an express balance wheel sorting machine.

[0062] Figure 1 A schematic diagram of an apparatus 100 for implementing a control method for a parcel balance wheel sorting machine according to an embodiment of the present disclosure is shown. Apparatus 100 includes a computing device 11, a data acquisition device 12, and a monitored device 13. The monitored device includes multiple balance wheel discs of the parcel balance wheel sorting machine and a belt drive mechanism for each balance wheel disc. In some embodiments, computing device 11, data acquisition device 12, and monitored device 13 are communicatively connected, either directly via a physical connection via a network cable or by exchanging data over a network.

[0063] The computing device 11 is configured to control the device to receive information data regarding a cargo sorting path and generate control instructions for the cargo sorting path, the control instructions including an angle deflection control instruction for each pendulum wheel in the sorting path and a second motor rotation speed control instruction for rotating four wheels in a belt transmission mechanism driving each pendulum wheel;

[0064] The computing device 11 is further configured to calculate the angular deflection angle of each of the plurality of pendulum discs, adjust the sorting path of the goods, and ensure a stable posture of the goods; based on the angular deflection control, while ensuring that the forces exerted on the goods by each roller by the goods during the transportation process are balanced, generate a synchronous control instruction for the optimal real-time transmission linear speed of the goods; and, under the transmission balance constraint between the driving wheel, the tensioning wheel, and each driven wheel, construct a multi-objective dynamic optimization function to solve the optimal real-time rotation speed of the driving wheel that minimizes the coupled vibration torque on each belt section, thereby achieving minimum shear vibration and maximum transmission efficiency for the four wheels in the belt transmission mechanism of each pendulum disc.

[0065] In some embodiments, the computing device 11 may include one or more processing units, including specialized processing units such as a GPU (Graphics Processing Unit), an FPGA (Field Programmable Gate Array), and an ASIC (Application Specific Integrated Circuit), as well as general-purpose processing units such as a CPU. Furthermore, one or more virtual machines may also be running on each control device 110. In some embodiments, the computing device 11 may include, for example, a path information receiving module 110, a control instruction generation module 112, a pendulum angle control module 114, a cargo transport line speed control module 116, and a shear vibration control module 118.

[0066] The path information receiving module 110 is configured to control the device to receive information data on the cargo sorting path.

[0067] The control instruction generation module 112 is configured to generate control instructions for the cargo sorting path, including an angular deflection control instruction for each pendulum wheel in the sorting path and a second motor rotation speed control instruction for rotating four wheels in a belt transmission mechanism that drives each pendulum wheel.

[0068] The pendulum wheel angle control module 114 is configured to calculate the angular deflection angle of each of the plurality of pendulum wheels, adjust the sorting path of the goods and ensure the stability of the goods.

[0069] The cargo transport line speed control module 116 is configured to generate synchronous control instructions for the optimal real-time transmission line speed of the cargo based on the angle deflection control, while ensuring that the forces exerted on the cargo by each roller during the cargo transportation process are balanced.

[0070] The shear vibration control module 118 is configured to construct a multi-objective dynamic optimization function under the transmission balance constraints between the driving wheel, the tensioning wheel and each driven wheel, and solve the optimal real-time rotation speed of the driving wheel that minimizes the coupled vibration torque on each belt section, so as to achieve minimum shear vibration and maximum transmission efficiency of the four wheels in the belt transmission mechanism of each pendulum wheel.

[0071] Regarding the data acquisition device 12, the pendulum wheel deflection angle and cargo center position monitoring device therein is used to monitor in real time the rotation angle of multiple pendulum wheels located in the same plane of the express pendulum wheel sorting machine, as well as the real-time position of the cargo center point in the three-dimensional coordinate system of the express pendulum wheel sorting machine when the cargo passes through the multiple pendulum wheels located in the same plane according to the target path. It can be an angle sensor (such as a magnetic encoder, a photoelectric encoder, etc.) installed on the top or side wall of the cargo transfer channel on the multiple pendulum wheels, preferably a ToF sensor, which can be a ToF sensor or a ToF sensor array composed of multiple ToF sensors, which continuously collects the real-time deflection angle of the pendulum wheel. and the three-dimensional coordinates of the cargo's center of mass.

[0072] As for the monitoring device of the rotational angular velocity of each wheel in the belt transmission mechanism, a magnetic encoder can be used;

[0073] Regarding the disturbance frequency monitoring equipment of the belt transmission mechanism, a vibration acceleration sensor can be selected for real-time monitoring.

[0074] Regarding the monitoring equipment for the lateral disturbance amplitude and longitudinal disturbance amplitude of the belt, for example, a laser displacement sensor can be selected to monitor them in real time.

[0075] Figure 2 A flow chart of a control method 200 for an express pendulum wheel sorting machine according to an embodiment of the present disclosure is shown, comprising the following steps:

[0076] In step 202, the control device 11 receives information data on the cargo sorting path; specifically, Figure 1 The control device 11 of the express oscillating wheel sorter shown first receives task information data related to the target cargo sorting path. This task information may include cargo type, sorting destination, sorting priority, cargo size, and weight. Based on this basic data, the system automatically parses the specific sequence and sorting time window of the six (or more) oscillating wheels that need to pass through the sorting path, providing a data foundation for subsequent control logic.

[0077] In step 204, control instructions for the cargo sorting path are generated. These control instructions include angular deflection control instructions for each pendulum disk in the sorting path, linear velocity control instructions for cargo delivery, and second motor rotational speed control instructions for the four wheels in the belt drive mechanism that drives each pendulum disk. The control device 110 generates targeted control instructions for each pendulum disk based on the received sorting path data. These instructions include (but are not limited to): real-time angular deflection control instructions for each pendulum disk, linear velocity control instructions for cargo delivery, and synchronous speed instructions for the transmission rollers within each pendulum disk. Specifically, based on the actual spatial distribution of each sorting point in the cargo path, the cargo size, and the positioning accuracy requirements, the system automatically assigns target angles, calculates the required rotational speed for each roller, and generates underlying motor control signals for driving the first motor (for driving the pendulum disk deflection) and the second motor (for driving the four transmission rollers).

[0078] In step 206, the control device 11 uses the path data for the cargo sorting path to calculate the angular deflection angle of each of the multiple pendulum discs, adjust the cargo sorting path, and ensure the cargo's stable posture. Specifically, the control device 11 further utilizes the sorting path data and the current state feedback of each pendulum disc to calculate the target deflection angle of each pendulum disc in real time. To ensure the cargo's stable posture during the sorting process, the control device 110 not only considers the sorting path planning but also dynamically adjusts the target deflection angle based on the initial reference angle of each pendulum disc, actual motion boundary conditions (such as maximum allowable angle, collision protection, etc.), and cargo inertia. It automatically corrects for deviations caused by disturbances, friction, and external force changes, achieving high-precision and flexible sorting control throughout the entire process.

[0079] In step 208, after completing the aforementioned angle deflection planning, the control device 11 generates synchronization control instructions for the four transmission rollers on each swing wheel disc based on the angle deflection control and the current sorting status (e.g., cargo arrival, acceleration, deceleration, departure, etc.). This instruction not only includes the target transmission speed of each swing wheel disc's four rollers but also an adaptive adjustment algorithm to maintain balanced cargo force and avoid slippage, local overload, or idling. Based on the cargo's real-time force, position, and motion state, the system implements multi-roller coordinated control through a built-in torque balance equation and friction compensation model, ensuring uniform force throughout cargo transportation and further improving sorting accuracy and reliability.

[0080] In step 210, the system establishes a multi-objective dynamic optimization function for the relative transmission relationships between the belt segments and the tensioner, driving, and driven pulleys, with minimizing the total shear coupling torque as the dynamic optimization objective. By modeling the dynamic constraints between the driving and tensioner pulleys and each driven pulley, the control device 11 solves for the optimal real-time speed of the driving pulley, minimizing the shear coupling vibration torque of each belt segment. This effectively suppresses local vibration energy loss caused by shear elastic delay, velocity disturbances, and relative slip, ultimately achieving synchronous drive of the four rollers of each pendulum disc, further improving the overall transmission efficiency, energy stability, and operational robustness of the sorting system.

[0081] This method can dynamically adapt to the sorting needs of goods of different batches, weights, and sizes. While ensuring efficient and stable sorting, it also significantly improves the system's energy efficiency and extends the service life of key moving components. Generally, the goods sorted by express delivery can be categorized as light goods weighing less than 5kg, medium goods weighing 5kg to 20kg, and heavy goods weighing 20kg to 30kg.

[0082] although Figure 2 The various steps shown in the embodiment perform the corresponding functions of the performance recommendation method in a specific order, but it can be understood that Figure 2 The steps in the method 200 may be performed in a different order relative to the order shown. For example, two or more steps shown in succession may be performed simultaneously or some steps may be performed simultaneously. In addition, certain steps in the method 200 may also be omitted.

[0083] Additionally, other steps can be added to Figure 2 It will be understood that all such variations are within the scope of the present disclosure.

[0084] As another aspect of the present disclosure, the method of using the path data for the cargo sorting path to calculate the angular deflection angle of each of the plurality of pendulum wheels, adjusting the cargo sorting path and ensuring a stable cargo posture includes:

[0085] A reference angle position of each pendulum disc is set in the mechanism coordinate system; a corresponding target deflection angle is calculated based on different pre-planned sorting routes; each first motor controlling the pendulum disc independently responds to a control instruction and adjusts the corresponding pendulum disc to the target deflection angle based on feedback from an angle sensor.

[0086] In some embodiments, Figure 3A flowchart illustrating a control method 300 for an express pendulum sorting machine according to an embodiment of the present disclosure is provided. The control device 110, according to the disclosed method, can independently send control instructions to the first motor of each pendulum disc and adjust the pendulum disc to a target deflection angle in real time based on feedback from the angle sensor, ensuring efficient and smooth transport of each item during the sorting process. The first motor of each pendulum disc independently receives control instructions and adjusts the corresponding pendulum disc to the target deflection angle based on feedback from the angle sensor, including:

[0087] In step 302, the control device 110 first arranges multiple angle sensors on the pendulum discs in conjunction with the top or side wall of the cargo delivery channel, and the system can obtain the three-dimensional coordinates (x s ,y s ,z s ) and the center of the pendulum wheel and the spatial position of each roller, to automatically determine the spatial distribution of each cargo during the sorting process, the status of the loading and unloading areas. All raw collected data is summarized in real time by the data acquisition module and transmitted to the control device 110;

[0088] According to the real-time deflection angle θ of each pendulum wheel s (t), and its target deflection angle range θ s ∈[θ0-θ m ,θ0+θ m ]; where θ0 represents the initial reference angle of the balance wheel, that is, the initial reference angle of the balance wheel in the unstressed state or in the control system; θ m Indicates the maximum deflection angle increment of the balance wheel; during the operation of the balance wheel, θ m It refers to the maximum deflection angle change allowed by the balance wheel during loading or unloading, starting from the reference angle θ0. m It indicates the maximum angle that can be reached by deflecting in the loading direction starting from the reference angle θ0. At this angle, the friction torque M Load The output torque of the first motor required when the balance wheel reaches its maximum positive load state, that is, the maximum load it bears in the loading area; θ0-θ m It represents the limit angle of deflection in the unloading direction starting from the reference angle θ0; at this angle, the friction torque M Unload The output torque of the first motor required when the balance wheel reaches its maximum reverse load state, that is, the maximum load it bears in the unloading area;

[0089] like This indicates that the balance wheel is in the loading area, that is, it is approaching the target deflection angle direction; if It indicates that the balance wheel is at rest; if This indicates that the pendulum is in the unloading area, that is, it is gradually moving away from the target deflection angle direction; define the real-time deflection angular velocity The symbolic function as follows:

[0090]

[0091] In step 304, the control device 110 determines the friction torque compensation amount for each balance wheel disc's real-time deflection angle within the target deflection angle range:

[0092]

[0093] Among them, C l 、C u are the friction torque compensation in the loading area and unloading area respectively; K l , K u are the stiffness coefficients of the pendulum in the loading and unloading areas respectively; β is the angular attenuation coefficient; for small packages weighing less than 5kg in the logistics sorting system, β = 0.02 ~ 0.08 rad -1 , K l =30~80N·m / rad, K u = 25 to 70 N·m / rad; for medium-sized packages weighing 5 to 20 kg, β = 0.1 to 0.3 rad -1 , K l =150~400N·m / rad, K u =100~300N·m / rad; for large packages weighing 20kg~30kg, β=0.3~0.5rad -1 ;K l =400~800N·m / rad, K u =350~700N·m / rad;

[0094] In step S306, the control device 110 calculates the first motor drive M required for each balance wheel in the loading area by combining the angle change, inertia response and friction compensation amount collected in real time. Load :

[0095]

[0096] Calculate the first motor driving torque M required by the balance wheel in the unloading area Unload :

[0097]

[0098] Then the first motor driving torque required for each pendulum wheel is obtained:

[0099] δ l and δ uare the nonlinear correction coefficients of the torque in the loading area and the nonlinear correction coefficient in the unloading area, δ l ∈[0.13,0.75],δ u ∈[0.13,0.75]

[0100] In step 308, the first motor energy consumption E is constructed within a period T of the goods being sorted on the mechanism. d The optimal real-time rotation angle θ of the pendulum wheel at the minimum value s,best (t) Solve the model:

[0101] in,

[0102] when When , it indicates that the torque given to the pendulum by the first motor assists the cargo to move toward the target direction in the area (i.e., the loading area), that is, it assists the cargo to accelerate. Therefore, the friction torque M output by the first motor in the loading area is Load is the positive torque, when When , it indicates that the torque given to the pendulum by the first motor assists the friction torque M of the cargo in this area (i.e., the unloading area). Unload The friction force is opposite to the force required to deflect the target angle. The friction force is the torque opposite to the direction of motion. Therefore, M Unload is the reverse driving torque in the opposite direction of the balance wheel rotation, which is a negative value. Therefore, the calculation of Ed is relative to the minimum value of the total work of the first motor calculated within the cycle length T, that is, |M Load (t)|+|M Unload The minimum value of (t)|

[0103] Figure 4 It shows that during the express sorting process, the weight of goods less than 5kg increases with the s (t) Friction index compensation item when changing within the range of -0.7854rad to 0.7854rad: Loading zone friction index compensation item Unloading zone friction index compensation Negative value changes of It increases exponentially in the range of 0.35 to 4.06. It increases exponentially in the range of -4.03 to -0.34.

[0104] Figure 5 The friction index compensation item is shown for goods weighing 5kg-20kg during express sorting. It increases exponentially in the range of 0.39 to 4.31. It increases exponentially in the range of -5.19 to -0.48.

[0105] Figure 6 The friction index compensation item is shown for goods weighing 20kg-30kg during express sorting. It increases exponentially in the range of 0.51 to 3.30. It increases exponentially in the range of -6.32 to -1.55.

[0106] Depend on Figure 4-Figure 6 It can be seen that the friction index compensation term in the loading area The closer to θ0-θ m , the larger the value of this item is, the friction compensation is started when the cargo enters the loading area as a load. s As the load increases, the positive torque in the driving torque output by the first motor needs to continue to increase to overcome the additional load between the cargo and the deflection of the pendulum disc, so the loading area friction index compensation term It is used to approximately compensate for the additional energy consumption and nonlinear friction torque caused by friction and rigidity in the starting and low-speed stages, which is particularly obvious when the balance wheel is driven by the first motor to start and switch directions.

[0107] Unloading zone friction index compensation The closer to θ0+θ m The smaller it is, the closer it is to θ0-θ m The smaller the value, the faster the reverse torque (used to drag and release the cargo) required by the driving torque output by the first motor decreases in the unloading area. Therefore, the friction index compensation item in the unloading area is It is mainly used to compensate for the energy loss and nonlinear friction resistance caused by friction and viscosity between the pendulum disc and the cargo during unloading (i.e. the pendulum disc rotates to its initial position), so that the torque output by the first motor can better counteract the energy loss and output delay under actual working conditions.

[0108] Figure 7 The figure shows the change of the first motor driving torque Mt during the express sorting process of goods with different weight ranges. The first motor driving torque Mt in the loading area of ​​goods weighing less than 5kg is Load The maximum value of the torque varies from 29.29N·m to 81.14N·m. The first motor driving torque M in the unloading area Unload The first motor driving torque M in the loading area of ​​the cargo weighing 5kg-20kg varies within the range of 24.45N·m to 71.57N·m. Load The maximum value of the torque varies in the range of 160.55N·m to 431.05N·m. The first motor driving torque M in the unloading area UnloadThe first motor driving torque M in the loading area of ​​the cargo weighing 20kg-30kg varies within the range of 107.44N·m to 324.32N·m. Load The maximum value of the torque varies from 427.65N·m to 856.33N·m. The first motor driving torque M in the unloading area Unload It varies within the range of 376.29N·m to 753.80N·m. Figure 7 Indicates the acceleration through the deflection angle of the balance wheel The symbolic function After dividing the force of the cargo on the pendulum disc into zones, the directional compensation of torque and the dynamic optimal energy consumption distribution are realized, and the amplitude C of the friction torque index compensation item in the loading area is l and C u And the specific motor drive torque M Load 、M Unload Modeling is done separately to avoid the error caused by the integrated linear model, and The nonlinear correction of the friction torque exponential term is performed (dynamic adjustment of the shear friction resistance that changes with the angle growth is achieved), combined with The attenuation model (which accurately describes the stick-slip critical transition process in the small-angle micro-start stage) and the stiffness penalty linear model fully describe the micro-start friction dynamics under the shared platform for the first time. The two together construct a high-fidelity friction torque response curve with hysteresis characteristics, friction-recovery asymmetry and angle sensitivity control capabilities, which is suitable for the express roller pair point contact dynamic model, and makes path planning based on the energy consumption integral. This method effectively avoids the error accumulation and energy waste caused by the "averaging" of load response differences in different regions in the traditional integrated linear control model.

[0109] Figure 8 A flow chart of a control method 400 for an express pendulum wheel sorting machine according to an embodiment of the present disclosure is shown. While ensuring that the forces exerted on the goods by each roller during the goods transmission process are balanced, a synchronous control instruction for the optimal real-time transmission linear speed of the goods is generated, i.e., synchronous control instructions for the four rollers on each of the six pendulum wheel discs are generated, including:

[0110] Based on the real-time deflection angle θ of the first motor at the lowest energy consumption during a sorting cycle T of a product being sorted s,best (t), calculate the real-time kinetic energy T of the cargo c and the normal force Q of the roller on each pendulum wheel i,j , used to analyze the stress conditions of cargo transportation;

[0111] Establish the real-time dynamic equation of cargo movement by integrating the normal force Q on each pendulum wheel i,jand friction to determine the force and acceleration changes on the cargo, which is used to dynamically control the cargo transportation speed;

[0112] Construct a torque balance equation for the cargo on each pendulum disc. By analyzing the friction torque and balance torque, determine the torque distribution during roller transmission, and use it to control the stability of the pendulum disc during rotation. Specifically, the forces on the four rollers of each pendulum disc are balanced in real time.

[0113] Applying the Pontryagin maximum method, taking the constructed Hamiltonian H as the optimization target, the optimal real-time linear velocity v of the cargo in the transmission path through the pendulum wheel is solved. c,best , used to minimize energy consumption.

[0114] Specifically, in step S402, based on the obtained real-time deflection angle θ of the first motor at the lowest energy consumption during the sorting cycle T of a cargo being sorted, s,best (t), the calculated mass is m c The real-time kinetic energy of the cargo T c , and the normal force Q distributed to the four rollers on the i-th balance wheel in real time i,j ;

[0115]

[0116] Among them, R c is the equivalent radius of the transported goods, that is, the distance between the center of mass of the transported goods and the center point of the i-th pendulum wheel,

[0117] Among them, α i , β i and γ i are the offset angles of the cargo center from the center point of the i-th balance wheel in the xy plane, xz plane, and yz plane respectively; v c x, v c y and v c z is the linear velocity vector v of the cargo along the x-axis, y-axis and z-axis of the three-dimensional coordinate system of the mechanism c The weight; v c is the real-time linear speed of the goods; T c As kinetic energy, its unit is kg·m 2 / s 2 ;

[0118] The real-time linear velocity vector v of the cargo in the three-dimensional coordinate system of the mechanism in the above steps is c , the deviation angle α of the cargo center from the center point of the i-th balance wheel in the xy plane, the xz plane and the yz plane i , β i and γ iand the real-time position of its own center of mass (x s ,y s ,z s ) and the coordinate position of the jth roller of the i-th pendulum wheel (x i,j ,y i,j ,z i,j ) are all collected uniformly by the TOF sensor,

[0119] The TOF sensor is installed at the top of the wheel sorting channel, looking down vertically to cover the entire conveying path. If the height of the goods is high or the path is long, a multi-sensor array layout can be used to achieve blind spot coverage. Several TOF sensors emit infrared light, detect the flight time of the return light, generate three-dimensional point cloud data, and use point cloud data processing algorithms (such as PCL library) to obtain the real-time center of mass position coordinates (x s ,y s ,z s ), and can cover the center point coordinates of each balance wheel (x i ,y i ,z i ) and its corresponding four roller positions (x i,j ,y i,j ,z i,j ), ensuring that each roller and cargo can be scanned, and further obtaining α i , β i and γ i : α i , β i and γ i The unit is rad.

[0120] In step S404, the real-time movement dynamics equation of the cargo is constructed as:

[0121]

[0122] Among them, Q i,j is the normal load on the jth roller of the i-th balance wheel, Q i,j =m c gcos(α i )cos(β i )cos(γ i ), unit is kg·m / s 2 , m c is the mass of the cargo, in kg; g is the acceleration due to gravity; μ slip is the sliding friction coefficient; v c is the real-time linear speed value of the goods; is the friction generated by the cargo during the operation of the mechanism; L i,jis the distance between the center of mass of the cargo and the jth roller of the i-th pendulum wheel, j = 1, 2, 3, 4;

[0123] When the packaging material of the transported goods is cartons or paper shells, for light goods (small packages weighing less than 5kg), μ slip =0.3~0.4; for medium-sized goods, i.e., weight 5kg~20kg, μ slip =0.4~0.55; for heavy goods, i.e. goods weighing 20kg~30kg, μ roll =0.55~0.7. When the packaging material of the transported goods is plastic, for goods of different weights, μ slip It is 80% to 85% of the friction coefficient when the packaging material is a carton or paper shell.

[0124] In step S406, the torque balance equation when the goods are transferred on the i-th pendulum wheel is constructed as follows:

[0125]

[0126] Among them, d i,j,x d i,j,x are the distances between the center of mass of the cargo and the jth roller of the i-th pendulum wheel in the x-axis direction and the y-axis direction respectively; d i,j,x =x s -x i,j , d i,j,y =y s -y i,j ;μ roll is the friction coefficient between the cargo and the roller;

[0127] When the packaging material of the transported goods is carton or paper shell, the roller material is polyurethane or rubber. For light goods, small packages weighing less than 5kg, μ roll =0.4~0.6; for medium-sized goods, i.e., weighing 5kg~20kg, μ roll =0.5~0.7; for heavy goods, i.e. goods weighing 20kg~30kg, μ roll =0.6~0.8; When the packaging material of the transported goods is plastic, and the roller material is the same, for goods of different weights, μ roll It is 80% to 85% of the friction coefficient when the packaging material is a carton or paper shell.

[0128] In step S408, based on the real-time dynamics equation of the cargo movement constructed in step S404 and the torque balance equation constructed in step S406, the Pontryagin maximum method is used to solve the optimal real-time linear velocity v that minimizes the time required to transport a cargo through multiple pendulum discs. c,best , the Hamiltonian H constructed when solving is:

[0129]

[0130] Where λ is the co-state variable coefficient, λ≤0;

[0131] reflects the constraint of system dynamics on the total cost. By the maximum principle, let The optimal cargo moving kinetic energy T can be obtained c,best , and then derive the optimal velocity vector v c,best , v c,best =‖v c,best ‖.

[0132] The constant term in the Hamiltonian H above represents the instantaneous cost in the shortest-time optimization problem. In time-optimal control based on the Pontryagin maximum principle, the goal is to minimize time. Therefore, the "cost" at each moment is 1, and the cumulative integral is the total time. λ is the co-state (conjugate variable), reflecting the constraint sensitivity of the current system state to the optimal goal and is a core variable in dynamic optimization of control systems. It means that in the process of constructing the Hamiltonian two-H, the dynamic effects are normalized, that is, all subsequent force or energy terms are standardized according to the package mass in order to unify the actual contribution affecting the velocity / acceleration. This item actually distributes kinetic energy equivalently into force, that is, the equivalent driving force of the package kinetic energy and structural distribution. It can be regarded as converting the kinetic energy Tc of the click output into an equivalent driving force for each roller through structural parameters (equivalent radius, distance from roller to center of mass). This is an approximate structural weighted distribution method. The structure of the Hamiltonian reflects the force-energy-friction-structure coupling in the sorting process, and realizes the integrated description of the physical process and the control target (shortest time). It integrates all the dynamic and structural variables that affect the package speed into an optimization framework. By applying the Pontryagin maximum method, the control problem (such as optimal speed planning) is converted into a Hamiltonian extreme value problem, and the control input is taken to the extreme value (maximum / minimum) according to the Hamiltonian, so as to obtain the optimal real-time control strategy.

[0133] In the time optimal control problem, the step control theory is used to calculate the optimal real-time linear speed v c,bestTo solve, first control the multiple balance wheels driven by the second motor under the drive of the belt to control the input driving force T c At the boundary value T max and 0, this stage is the acceleration stage, until the co-state variable coefficient λ reaches 0. When it is in the exponential acceleration state, λ(t)<0, the optimal velocity vector v is obtained at this time. c,best =(v cx,best (t),v cy,best (t),v cz,best (t)).

[0134]

[0135] When in a uniform acceleration state, λ(t) = 0, then the optimal velocity vector v is obtained c,best The quantities are as follows:

[0136]

[0137] Among them, T max is the maximum output torque of the first motor, in N·m; k t is the motor torque constant, in N·m / A); I max The maximum allowable current of the motor, in A.

[0138] The express pendulum sorting machine used in the disclosed method is a flexible logistics equipment that has multiple pendulum discs and realizes the diversion of packages along a set trajectory through the dynamic deflection angle and synchronous drive of multiple electric pendulum discs (each containing multiple drive rollers). Each pendulum disc is driven by two types of motors in a coordinated manner: the first motor adjusts the angle of the corresponding pendulum disc body, and the second motor drives several rollers on each pendulum disc to move the items forward. Sorting process: When the goods just enter the sorting area, the rollers need to accelerate the goods to the target speed in a short time, and at the same time dynamically adjust the deflection angle to ensure smooth and controllable diversion.

[0139] In the exponential acceleration state (i.e., exponential acceleration state movement for a period of time followed by constant speed uniform motion), the optimal real-time motion speed v along the x-axis direction is cx,best (t) as an example:

[0140]

[0141] When the goods first enter the sorting mechanism, the roller is at the maximum safe motor torque T max Under the action of μ, the system friction (determined by the friction coefficient, normal force, and the deflection angle of the pendulum) is overcome to accelerate the package. The spatial distribution of the cargo and the pendulum / roller has a direct effect on the lever effect and torque distribution, affecting the acceleration and speed response of the cargo being transferred. slipcos(θ s,best )∑Q i,j It comprehensively reflects the actual friction resistance between all rollers and the goods at different deflection angles, and is the physical bottleneck and safety constraint of the sorting mechanism operation.

[0142] Figure 9 The figure shows the expected value (blue dashed line) of the optimization model of the disclosed method, the expected value (purple dashed line) of comparative example 1 using the fuzzy adaptive control method, and the measured value (red solid line) of the model when transporting goods of different weight ranges under exponential acceleration, first performing uniform motion and then accelerating at a constant acceleration under the condition of varying output torque of the first motor. Figure 9 (a) Figure 9 (b) and Figure 9 The upper figure in (c) shows the velocity change curves when the balance wheel is deflected from its initial position of 0° to 45° or -45°, and the lower figure shows the velocity change curves when the balance wheel swings to the desired limit of deflection angle and then reverses (i.e., rotates) to its initial position.

[0143] Figure 9 (a)- Figure 9 (c) The measured values ​​for the cargo, represented by the solid red line, show a trend of gradually accelerating acceleration during the forward and reverse rotation of the pendulum disc. The red measured values ​​all rise rapidly to a certain value (0.34 m / s for cargo weighing less than 5 kg, 0.26 m / s for cargo weighing between 5 kg and 20 kg, and 0.2 m / s for cargo weighing between 20 kg and 30 kg). The method employed in this disclosure exhibits a smooth step response with no significant overshoot in the initial stage. Comparative Example 1 underestimates the limit of the speed increase. As the cargo mass increases, the maximum speed reached during the exponential acceleration phase gradually decreases, while Comparative Example 1 exhibits a significant deviation from the measured values. Therefore, the solution for the exponential acceleration state conforms to the initial state, where time t is small, the system acceleration is large, and the speed increases over time. As t increases, friction and structural constraints gradually dominate, and the speed tends to plateau, i.e., the requirement for uniform speed. This dynamic process is highly consistent with a first-order inertial system (e.g., acceleration under viscous damping), reflecting the engineering logic of the sorting mechanism: "flexible start followed by smooth diversion." The method disclosed in the present invention can achieve stable speed at the millisecond level under light load and quickly complete sorting. By embedding the mass mc into the dynamic equation of the control model, adaptive adjustment of acceleration is achieved, and the bang-bang control optimization strategy of Pontryagin extreme value solution is adopted to ensure the accuracy of solving the shortest acceleration path under limited energy consumption. The friction hysteresis model of different cargo weights is further integrated to avoid vibration of the output results.

[0144] In the state of uniform acceleration (i.e., first move at a constant speed for a period of time and then move at a constant acceleration), Figure 10 The figure shows the expected value (blue dashed line) of the optimization model of the disclosed method, the expected value (purple dashed line) of comparative example 2 using the PID control method, and the measured value (red solid line) when the cargo of different weight ranges is transported under exponential acceleration, first in a constant speed uniform motion and then in an accelerated motion with constant acceleration under the condition of a change in the output torque of the first motor. Figure 10 (a) Figure 10 (b) and Figure 10 The upper and lower figures of (c) are as follows Figure 9 The upper and lower pictures Figure 1 Similarly, this is also the speed value when the balance wheel rotates forward and reverse.

[0145] Figure 10 (a)- Figure 10 The measured value of the cargo shown in (c) is represented by the solid red line. During the forward and reverse uniform acceleration, when the output torque varies within the range of 0-5 N·m, the acceleration is 0, and the initial uniform motion is performed. After that, it shows a rapid upward (forward) or downward (reverse) trend. The maximum speed of cargo weighing less than 5 kg is ±0.7 m / s. The speed increase of cargo weighing 5 kg-20 kg is slower than that of cargo weighing less than 5 kg, with a maximum speed of ±0.55 m / s. The speed response of cargo weighing 20 kg-30 kg is further weakened, with a maximum speed of only about ±0.4 m / s. Figure 10 As can be seen, the measured values ​​of the new model under uniform acceleration for cargo in different weight ranges show little deviation from the expected values, demonstrating good fitting accuracy. However, the expected values ​​of Comparative Example 2 deviate significantly from the actual measured values ​​in the medium-to-high torque range, with significant response hysteresis. This shows that if the express sorting mechanism does not have any frictional resistance, the roller will linearly increase the package speed at the acceleration corresponding to the maximum motor output torque, i.e., a uniform-constant acceleration process. In real-world sorting, cargo is constrained by friction between the roller, itself, and the surface of the mechanism. In the early stages of the sorting process (when time t is small), the impact of friction is not significant, and the speed increases approximately linearly; however, over time, the impact of friction gradually intensifies, and the speed increase slows. The bang-bang control strategy based on the Pontryagin maximum method adopted in this disclosure closely fits the actual speed data under all three weight conditions, significantly reducing speed errors and meeting the requirements of high-speed sorting. It can also effectively and quickly switch between push / resistance sections within the sorting path, achieving a control strategy with minimal energy consumption and the shortest time. Compared with existing technologies, it better handles problems such as nonlinear friction, hysteresis response, and acceleration saturation under different load conditions.

[0146] Based on the structural distribution and mechanical constraints of the pendulum disc sorting mechanism, this paper proposes two optimal speed control strategies for the sorting startup process: exponential acceleration and uniform acceleration. The former simulates the flexible startup and platform speed stabilization process of the sorting system under the coupling of friction resistance and mechanism inertia, achieving smooth parcel diversion. It is suitable for sorting scenarios with heavy parcels, high mechanism friction and inertia, and strict requirements on cargo posture and startup impact. It effectively prevents parcels from slipping, rolling, or losing control due to instantaneous excessive thrust, improving sorting accuracy and system stability. The latter is more suitable for flexible slow-start sorting, balancing safety and stability. It focuses more on efficient sorting under ideal conditions, using linear acceleration dominated by motor driving force and corrected by actual friction. It is suitable for sorting scenarios with extremely high requirements for sorting speed and efficiency.

[0147] As another aspect of the present disclosure, Figure 11 A flow chart of a control method 500 for an express balance wheel sorting machine according to an embodiment of the present disclosure is shown. The method constructs a multi-objective dynamic optimization function under transmission balance constraints between the driving wheel, the tensioning wheel, and each driven wheel to solve the optimal real-time rotation speed of the driving wheel that minimizes the coupled vibration torque on each belt section, including:

[0148] Based on the acquired real-time rotation angle of each wheel in the belt transmission mechanism, the wrap angle parameters of each wheel and the disturbance angular frequency of the transmission system, the instantaneous motion state of the belt and each wheel is analyzed to achieve real-time perception of the disturbance working condition of the transmission system of each pendulum wheel;

[0149] Establish the belt stable transmission balance equation of the driving pulley, tensioning pulley and driven pulley to dynamically limit the energy and speed transfer between each wheel of the system and realize the modeling of the multi-wheel coordinated transmission relationship;

[0150] Based on the elastic response and slip characteristics of the shear layer of the belt segment, a multi-objective dynamic optimization model is constructed. The minimization of the total shear torque of each belt segment is optimized to optimize the driving force and speed distribution of the driving wheel. Ultimately, the optimal real-time rotational angular velocity control command of the driving wheel is obtained to minimize the overall energy consumption and vibration.

[0151] Figure 12 The figure shows a courier balance wheel sorting machine controlled by the control device 110 of the present disclosure. The courier balance wheel sorting machine of the present disclosure includes several balance wheel mechanisms. Figure 13-14 It is shown that each of the balance wheel mechanisms includes a balance wheel plate 10, four rollers arranged on the balance wheel plate, a tensioning wheel 5, a driving wheel 6, a first motor 7, a second motor 8 and a transmission belt 9. The four rollers arranged on the balance wheel plate 110 include a first roller 1, a second roller 2, a third roller 3 and a fourth roller 4.

[0152] The first roller 1, the second roller 2, the third roller 3 and the fourth roller 4 are arranged clockwise around the center point of the balance wheel 10. Figure 13 The first roller 1 and the third roller 3 are coaxially connected via a transmission shaft 101. The second roller 2 and the fourth roller 4 serve as driven wheels, and together with the tensioning wheel 5 and the driving wheel 6, form a transmission system for each balance mechanism via a transmission belt 9. The inner ring of the transmission belt 9 is provided with a plurality of teeth. Gear sleeves are fixedly provided at both ends of the transmission shaft 101. Figure 15 The figure shows that the inner ring of the transmission belt 9 is provided with multiple teeth that engage with the teeth on the gear sleeve of the transmission shaft 101 near the third roller 3. During the transmission process, the transmission belt 9 drives the transmission shaft 101 to rotate in the same direction, thereby driving the first roller 1 and the third roller 3 to transmit in the same direction as the belt transmission mechanism; the driving pulley 6, the tensioning pulley 5, the second roller 2, the fourth roller 4 and the transmission belt 9 form a belt transmission mechanism;

[0153] The first motor 7 drives each pendulum disc to deflect on the cargo transfer plane, and the second motor 8 drives the driving wheel 6 to rotate, and then drives the four rollers to rotate through the transmission belt 9.

[0154] Specifically, the pendulum wheel angle control module controls several first motors 7, and the cargo transport linear speed control module and the shear vibration control module control several second motors 8, thereby completing the sorting of several pendulum wheels 10 according to the cargo sorting path at the optimal real-time linear speed to smoothly complete the sorting.

[0155] Figure 16 It is shown that the belt transmission mechanism in the express pendulum wheel sorting machine disclosed in the present invention is a closed-loop transmission mechanism of driving wheel 6→fourth roller 4→second roller 2→tensioning wheel 5→driving wheel 6, belt section A is the distance from the tangent point of the transmission belt 9 and the second roller 2 to the transmission belt 9 and the tensioning wheel 5, belt section B is the distance from the tangent point of the transmission belt 9 and the tensioning wheel 5 to the transmission belt 9 and the driving wheel 6, belt section C is the distance from the tangent point of the transmission belt 9 and the second roller 2 to the transmission belt 9 and the fourth roller 4, and belt section D is the distance from the tangent point of the transmission belt 9 and the fourth roller 4 to the transmission belt 9 and the driving wheel 6.

[0156] Specifically, in step S502, the real-time rotation angle of each wheel in the belt transmission mechanism, the disturbance angular frequency ω of the transmission system corresponding to a swing plate composed of each wheel and the belt, and the belt wrap angle α of each wheel are obtained. n ;

[0157] In step S504, the belt stable transmission balance equation of the second roller 2, the fourth roller 4, the tensioning pulley 5 and the driving pulley 6 is considered:

[0158] The stable transmission balance equation of the belt section of the second roller 2 is:

[0159]

[0160] The stable transmission balance equation of the belt section of the fourth roller (4) is:

[0161]

[0162] The belt segment stable transmission balance equation of the tensioning wheel 5 is:

[0163] k r The stiffness of the tensioner, that is, the tension applied by the tensioner to the belt requires a high restoring torque. k s is the tension wheel support stiffness, in N / m, the tension wheel support stiffness k of the small logistics sorting machine of the express conveyor line s Usually 10 2 ~1.5×10 3 N / m;

[0164] The stable transmission balance equation of the belt section of the driving wheel 6 is:

[0165]

[0166] k 6,Damp is the driving wheel damping stiffness, k 6,Damp =c·r6; c is the damping coefficient, in Ns / m. For express sorting lines, c is generally 1 to 15 Ns / m;

[0167] In step S506, a multi-objective dynamic optimization model for minimizing the total shear coupling moment is constructed:

[0168]

[0169] S total is the total shear coupling moment, S total =S A,52 (t)+S B,56 (t)+S C,24 (t)+S D,64 (t); S A,52 (t) is the shear coupling torque of the belt segment A between the tensioning wheel 5 and the second roller 2, S B,56 (t) is the shear coupling torque of the belt segment B between the driving pulley 6 and the tensioning pulley 5, S C,24 (t) is the shear coupling torque of the belt segment C between the second roller 2 and the fourth roller 4, S D,64 (t) is the shear coupling torque of the belt segment D between the driving wheel 6 and the fourth roller 4;

[0170]

[0171] Among them, ω b,m is the angular velocity of the fiber layer in the mth belt segment, ω b,m (t) abbreviation; ω m is the angular velocity of the mth belt segment, ω m ω m (t) abbreviation; ω g,m (t) is the average angular velocity of the mth belt segment, which is abbreviated as ω g,m ;m=A,B,C,D;

[0172] ω b,m (t) = ω m (t)-ω g,m (t);

[0173]

[0174] is the real-time angular velocity of the nth wheel (obtained from monitoring), n=2,3,4,5; r n is the radius of the nth wheel; the nth wheel is the wheel corresponding to the reference numeral n, n = 2, 3, 4, 5, therefore, the second wheel represents the second roller 2 corresponding to the reference numeral 2, the third wheel represents the third roller 3, the fourth wheel is the fourth roller 4, and the fifth wheel represents the tensioning wheel 5.

[0175]

[0176] The roller radii r2, r4, r5, and r6 are generally 50 mm to 100 mm. In some embodiments, r2 = r4 = r5 = r6, so there is no deceleration and the transmission ratio is 1:1; L A , L B , L C and L D They are the lengths of belt segment A, belt segment B, belt segment C, and belt segment D respectively.

[0177] The belt wrap angle α about the nth pulley n Calculation:

[0178]

[0179] C 65 represents the straight-line distance between the center point of the driving wheel 6 (i.e., the center of the circle) and the center point of the tensioning wheel 5 (i.e., the center of the circle), C 64 The straight-line distance between the center point of the driving wheel 6 and the fourth roller 4;

[0180]

[0181] C 42 represents the straight-line distance between the center point of the fourth roller 4 and the center point of the second roller 2;

[0182]

[0183] C 52 Represents the straight-line distance between the center point of the tensioning wheel 5 and the center point of the second roller 2;

[0184]

[0185] C 65 Represents the straight-line distance between the center point of the tensioning wheel 5 and the center point of the driving wheel 6;

[0186] When, in some embodiments, r2=r4=r5=r6, α n are all 180°, i.e. π. It should be noted that r n It is the radius of the gear that actually wraps around the belt, that is, the gear that transmits the power through tooth engagement.

[0187] A magnetic encoder is used to monitor the real-time rotational angular velocity of each wheel in the belt drive mechanism. The output signals of each sensor are connected to a PLC or MCU at the rotation axis of the second roller (2), the fourth roller (4), the driving wheel (6), and the tensioning wheel (5). The output signals of each sensor can be connected to the PLC or MCU and transmitted via RS485 or CAN bus to achieve centralized monitoring. The magnetic encoder can be the AS5048A from OSRAM. By using a synchronous sampling method within the PLC or MCU, the data acquisition time of each sensor is guaranteed to be consistent, thereby ensuring the consistency of the real-time angular velocity of each wheel.

[0188] The disturbance frequency ω is obtained by real-time monitoring using a vibration acceleration sensor, such as ADXL345 or a MEMS acceleration sensor (such as Bosch BMA280 or STMicroelectronics LIS3DH), which is provided on the driving wheel bearing seat.

[0189] The lateral disturbance amplitude (lateral vibration caused by belt tension fluctuations and load impact, vibration along the belt transmission direction) and longitudinal disturbance amplitude generated by the disturbance can be monitored in real time by a laser displacement sensor (Keyence LK-G series, SICKOD Mini series) installed on the side wall of the tensioner.

[0190] In step S508, under the constraints of the belt stable transmission balance equation of multiple transmission wheels in step S504, the multi-objective dynamic optimization model of belt transmission shear torque constructed in step S506 is solved to solve the optimal rotational angular velocity ω of the driving wheel. 6,best (t).

[0191] In the multi-objective dynamic optimization model of belt drive shear torque, S A,52 (t) as an example, the first Reflects the average slip loss and static energy consumption (s is the slip ratio) at both ends of belt segment A (tensioner 5 and driven pulley 2). This describes the energy loss during long-term stable operation and represents the fundamental resistance and loss of the belt-pulley system.

[0192] Item 2 It is a synchronous elastic response term that describes the synchronous elastic response of the system at the disturbance frequency and reflects the periodic influence of the angular velocity of the wheels at both ends of the belt segment (including dynamic disturbances) on the shear force of the system. It is used to measure the impact of synchronous vibration on the instantaneous mechanical response of the transmission system and is a key representation of the dynamic response of the system.

[0193] Item 3 This reflects the elastic wave propagation delay and high-frequency delayed response caused by the finite length (span) of the belt segment. It is the dynamic manifestation of the shear force propagating and superimposing along with the disturbance within the belt. It is used to characterize the energy transfer lag, fluctuation, and resonance at high frequencies. Adding this item enables precise control of the transmission system of each pendulum disc and increases system stability.

[0194] These three sub-items together describe the entire shear mechanical response of the belt segment due to slip, elasticity and dynamic propagation in actual transmission.

[0195] Figure 17 and Figure 18 The optimal rotational angular velocity ω of the driving wheel obtained by the method disclosed in this disclosure is shown 6,best (t) Variation of the lateral disturbance amplitude and longitudinal disturbance amplitude in the range of 200rad / min-600rad / min. The disclosed method (blue solid line) Figure 17 and Figure 18 The lateral disturbance amplitude and longitudinal disturbance amplitude represented by are always lower than the belt disturbance amplitude caused by the rotational angular velocity of the driving wheel obtained by CNN control, PID control and fuzzy adaptive control methods in the full speed range. For example, Figure 17The results show that at ω6(t) = 400 rad / min, the optimized method of the present application results in a lateral disturbance amplitude of approximately 1.7 mm in the belt, while the CNN control method results in approximately 1.8 mm, the fuzzy adaptive control method results in approximately 1.85 mm, and the PID control method results in the highest lateral disturbance, exceeding 2.1 mm. As the speed increases, the gap between the lateral disturbance caused by the PID control method and the lateral disturbance caused by the angular velocity of the driving wheel optimized by the other two existing technologies and the present application further widens. A similar trend is also observed for longitudinal disturbances, indicating that the present method can achieve optimal suppression of lateral and longitudinal disturbances by optimizing the real-time angular velocity of the driving wheel. Compared with traditional CNN control optimization methods, PID control optimization methods, and fuzzy adaptive optimization methods, although CNN control and fuzzy adaptive control have certain adaptive capabilities, they do not consider the physical nature of elastic hysteresis and pulley vibration energy consumption in actual multi-wheel transmission structures, rely solely on data / rule optimization, and are limited by model generalization. The present disclosure is based on dynamics and optimization theory. In the logistics pendulum transfer system, the vibration frequency of the belt segment directly affects the stability of the belt transmission system. If the disturbance frequency ω is too high, the tension in the belt segment will fluctuate greatly, further increasing the vibration amplitude of the system and reducing the transmission efficiency. By dynamically adjusting the driving force of the active wheel and the real-time speed distribution, quantitative optimal adjustment can be performed for different cargo / speed / damping conditions. By introducing multi-wheel constraints on the belt segment, minimization of the shear coupling torque and the fiber layer angular velocity perturbation model, multi-wheel-multi-belt coordinated control and comprehensive optimization of elasticity-damping are achieved.

[0196] In another embodiment, establishing the belt stable transmission balance equation of the driving pulley, the tensioning pulley and the driven pulley in step S504 includes determining the tension stiffness of multiple belt segments between the driving pulleys, the stiffness of the tensioning pulley and the damping stiffness of the driving pulley.

[0197] That is to determine the tension stiffness k of each belt segment A1 , k B1 , k C1 , k D1 , the stiffness k of the tensioner r and the damping stiffness k of the driving wheel 6,Damp ;

[0198] Where m = A, B, C, D; A cross The cross-sectional area of ​​the conveyor belt (the plane section perpendicular to the conveying direction), in m 2 ; E is the Young's modulus of the belt, which varies depending on the material of the conveyor belt. When it is made of rubber, E = 0.01~0.1GPa, that is, 0.01~0.1N / m2; when it is made of polyurethane, E = 0.05~0.3GPa; when it is made of nylon, E = 1.5~3GPa;

[0199] L m is the length of the mth belt segment, that is, the length between the tangent points of the mth belt segment and its two adjacent transmission wheels, in meters;

[0200] In another embodiment, the process of constructing the multi-objective dynamic optimization model in step S506 further includes determining the shear layer equivalent stiffness G of each belt segment. * :

[0201] Among them, H is the belt thickness, b is the belt width, L is the total length of the belt in the transmission system, G is the belt shear modulus, and the shear modulus G is an inherent property of the belt material. The commonly used shear moduli of belts of different materials are as follows: the shear modulus G of rubber material is 0.5×10 6 Pa~1.5×10 6 Pa range, shear modulus of polyurethane material G1×10 6 Pa~2.5×10 6 Pa range, the shear modulus G of nylon material is 2×10 6 Pa~3×10 6 Pa.

[0202] The flowcharts and step diagrams in the accompanying drawings show the possible architectures, functions and operations of the systems, methods and computer program products according to multiple embodiments of the present invention. In this regard, each step in the flowchart or step diagram can represent a module, program segment or part of an instruction, and a module, program segment or part of an instruction contains one or more executable instructions for implementing the specified logical function. In some alternative implementations, the functions marked in the steps can also occur in an order different from that marked in the accompanying drawings. For example, two consecutive steps can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each step in the step diagram and / or flowchart, and the combination of the steps in the step diagram and / or flowchart, can be implemented using a dedicated hardware-based system that performs the specified function or action, or can be implemented using a combination of dedicated hardware and computer instructions.

[0203] While various embodiments of the present invention have been described above, the above descriptions are intended to be illustrative, non-exhaustive, and not limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is selected to best explain the principles of the embodiments, their practical applications, or technological improvements in the marketplace, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A control method for an express balance wheel sorting machine, characterized in that: The following steps are involved: The control device receives information data on the cargo sorting path; generating control instructions for the cargo sorting path, the control instructions including an angular deflection control instruction for each pendulum wheel in the sorting path, a cargo transfer linear speed control instruction, and a second motor rotation speed control instruction for rotating four wheels in a belt transmission mechanism that drives each pendulum wheel; Using the path data for the cargo sorting path, calculating the angular deflection angle of each of the plurality of pendulum wheels, adjusting the cargo sorting path and ensuring a stable cargo posture; Based on the angle deflection control, generating synchronization control instructions for the four rollers on each pendulum wheel, the synchronization control instructions including transmission speed control of each roller to ensure that the force exerted by each roller on the cargo during cargo transportation remains balanced; Under the constraints of transmission balance between the driving pulley, tensioning pulley and each driven pulley, a multi-objective dynamic optimization function is constructed to solve the optimal real-time rotation speed of the driving pulley that minimizes the coupled vibration torque on each belt section. On the basis of ensuring the synchronous driving of the four transmission rollers of each pendulum wheel during the sorting process, the minimum shear vibration and maximum transmission efficiency of the four wheels in the belt transmission mechanism of each pendulum wheel are achieved.

2. The method according to claim 1, wherein The method of using the path data for the cargo sorting path to calculate the angle deflection angle of each of the plurality of pendulum wheels, adjusting the cargo sorting path and ensuring the stability of the cargo posture, includes: A reference angle position of each pendulum disc is set in the mechanism coordinate system; a corresponding target deflection angle is calculated based on different pre-planned sorting routes; each first motor controlling the pendulum disc independently responds to a control instruction and adjusts the corresponding pendulum disc to the target deflection angle based on feedback from an angle sensor.

3. The method according to claim 2, characterized in that Each first motor controlling the balance wheel independently responds to a control instruction and adjusts the corresponding balance wheel to the target deflection angle according to feedback from an angle sensor, including: According to the real-time deflection angle of each pendulum wheel, the cargo loading area and cargo unloading area of ​​each pendulum wheel and the real-time location are determined; Determining the friction torque compensation amount for each pendulum disc's real-time deflection angle within a target deflection angle range; Calculating the first motor driving torque required for each balance wheel; Determine the optimal real-time deflection angle of the pendulum wheel under the lowest energy consumption of the first motor during a sorting cycle in which a commodity is sorted.

4. The method according to claim 1, wherein The generating of the synchronous control instruction for the optimal real-time transmission linear speed of the cargo based on the angle deflection control while ensuring that the force exerted by each roller on the cargo during cargo transportation is balanced includes: Based on the real-time deflection angle of the first motor at the lowest energy consumption during a sorting cycle of a product, the real-time kinetic energy of the product and the normal force of the rollers on each pendulum disc are calculated to analyze the force conditions of the product during transportation; Establish a real-time dynamic equation for cargo movement. By integrating the normal force and friction force on each pendulum disc, the force and acceleration changes on the cargo are determined to dynamically control the cargo transportation speed. Construct a torque balance equation for the cargo on each pendulum disc. By analyzing the friction torque and the balance torque, determine the torque distribution during the roller transmission process, which is used to control the stability of the pendulum disc during rotation. The Pontryagin maximum method is applied to solve the optimal real-time linear velocity of the goods in the transmission path through the pendulum disk with the constructed Hamiltonian as the optimization objective, so as to minimize energy consumption.

5. The method according to claim 1, wherein The method constructs a multi-objective dynamic optimization function under the transmission balance constraint between the driving wheel, the tensioning wheel, and each driven wheel to solve the optimal real-time rotation speed of the driving wheel that minimizes the coupled vibration torque on each belt section, including: Based on the acquired real-time rotation angle of each wheel in the belt transmission mechanism, the wrap angle parameters of each wheel and the disturbance angular frequency of the transmission system, the instantaneous motion state of the belt and each wheel is analyzed to achieve real-time perception of the disturbance working condition of the transmission system of each pendulum wheel; Establish the belt stable transmission balance equation of the driving pulley, tensioning pulley and driven pulley to dynamically limit the energy and speed transfer between each wheel of the system and realize the modeling of the multi-wheel coordinated transmission relationship; Based on the elastic response and slip characteristics of the shear layer of the belt segment, a multi-objective dynamic optimization model is constructed. The minimization of the total shear torque of each belt segment is optimized to optimize the driving force and speed distribution of the driving wheel. Ultimately, the optimal real-time rotational angular velocity control command of the driving wheel is obtained to minimize the overall energy consumption and vibration.

6. The method according to claim 5, wherein The establishment of the belt stable transmission balance equation of the driving wheel, the tensioning wheel and the driven wheel includes determining the tension stiffness of multiple belt segments between the wheels, the stiffness of the tensioning wheel and the damping stiffness of the driving wheel.

7. The method according to claim 5, wherein The process of constructing the multi-objective dynamic optimization model also includes determining the shear layer equivalent stiffness of each belt segment.

8. A control device for an express balance wheel sorting machine, characterized in that: include: A path information receiving module is configured to control the device to receive information data on the cargo sorting path; a control instruction generation module configured to generate control instructions for the cargo sorting path, the control instructions including an angular deflection control instruction for each pendulum wheel in the sorting path and a second motor rotation speed control instruction for rotating four wheels in a belt transmission mechanism that drives each pendulum wheel; a pendulum wheel angle control module, configured to calculate the angular deflection angle of each of the plurality of pendulum wheels, adjust the sorting path of the goods and ensure the stability of the goods; The cargo transport linear speed control module is configured to generate a synchronous control instruction for the optimal real-time transmission linear speed of the cargo based on the angle deflection control, while ensuring that the force exerted on the cargo by each roller during the cargo transportation process is balanced; The shear vibration control module is configured to construct a multi-objective dynamic optimization function under the transmission balance constraints between the driving wheel, the tensioning wheel and each driven wheel, and solve the optimal real-time rotation speed of the driving wheel that minimizes the coupled vibration torque on each belt section, thereby achieving minimum shear vibration and maximum transmission efficiency for the four wheels in the belt transmission mechanism of each pendulum wheel.

9. A courier balance wheel sorting machine, characterized in that: A control device using the method according to claims 1 to 7, further comprising a plurality of balance wheel mechanisms, each of the balance wheel mechanisms comprising a balance wheel disc, four rollers arranged on the balance wheel disc, a tensioning wheel (5), a driving wheel (6), a first motor (7), a second motor (8) and a transmission belt (9), the four rollers arranged on the balance wheel disc comprising a first roller (1), a second roller (2), a third roller (3) and a fourth roller (4); the driving wheel (6), the tensioning wheel (5), the second roller (2), the fourth roller (4) and the transmission belt (9) constitute a belt transmission mechanism; The first motor (7) drives each pendulum wheel to deflect on the cargo transfer plane, and the second motor (8) drives the driving wheel (6) to rotate, and then drives the four rollers to rotate through the transmission belt (9).

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