Intelligent truss transfer system and transfer method for lead stack offline

Abstract

The invention relates to an intelligent truss transfer system and transfer method for lead stack offline, and belongs to the technical field of intelligent equipment.The intelligent truss transfer system comprises an offline truss, a ground checking scale and a transfer RGV; one end of the off-line truss is vertically bridged above a lead stack production line, the other end of the off-line truss is bridged above a running track of a transfer RGV, and the ground checking scale is arranged right below the middle part of the truss; the ground checking scale is formed by stacking two plane platform scales; a track for transferring the RGV is mounted on the ground, is vertical to the off-line truss and is parallel to a lead stack production line; according to the system, intelligent offline transfer of the lead stacks can be achieved, weighing and metering data are automatically stored in an upper computer management system, then the offline truss transfers the lead stacks to a transfer RGV to be put in storage, point-to-point transfer of the lead stacks is achieved, traditional manual forklift and crown block operation is replaced, manpower is replaced, the automation degree is improved, and the production efficiency is improved. And the risk of cross operation of equipment and manpower is avoided, and the investment of manpower cost is greatly reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of intelligent equipment, and in particular relates to an intelligent truss transfer system and a transfer method for lead stacks off-line. Background Art

[0002] Traditionally, lead stacks are manually lifted off the production line by forklifts or overhead cranes. Since each shift requires 6-8 hours of continuous production, multiple people are needed to assist in the manual forklifts and overhead cranes, carrying the stacks back and forth from the production line to the inventory area. Furthermore, manual quantity recording and inventory are required during the process of storage. During shipment, manual assistance is also required to lift the stacks from the warehouse and first transport them to the weighing platform. Labels printed by the labeling machine are then manually applied to both sides of the stack. The stacks are then lifted from the weighing platform and transported to the truck for loading and placement. Manual assistance is also required for unloading. Before loading, manual verification of truck information, printing of loading orders, and a manual inventory of the loading status are required.

[0003] The process of placing lead stacks in the warehouse is crucial. Due to the limited storage area, manual forklifts are required to place lead stacks gradually from the farthest to the nearest corner of the warehouse, and sufficient turning radius is required for the forklifts to facilitate U-turns. When manually counting lead stacks in inventory or sampling lead stacks, lead stacks within the warehouse are difficult to remove. Manual forklifts can only load lead stacks from one end of the warehouse and gradually move them toward the interior, and cannot select and load lead stacks based on the loading order.

[0004] If the crane is used to transport the lead stacks into the warehouse, the workers who hang and unload the crane hoist will need to walk back and forth from the lead stack offline point to the warehouse area, which increases the workload; or special personnel can be arranged to hang the lead stacks on the production line and unload the lead stacks in the warehouse area, which will increase the labor cost; when the lead stacks are shipped out of the warehouse, special personnel will need to be arranged on the truck to unload the lead stacks; if the lead stacks need to be shipped at the same time as production, there will be more cases of cross-operation between overhead cranes and manual workers, which increases many safety risks.

[0005] The traditional process of loading and unloading lead stacks involves manual recording and inventorying, which is prone to errors. Furthermore, manual processing of inventory and loading data is complex and requires multiple verifications and comparisons. For shipment labeling, the stack must first be manually lifted onto a scale using a forklift or overhead crane. The scale's weight information is then transmitted to a labeling machine for label printing. Labels are then manually affixed to both sides of the stack before the stack is forked or hoisted from the scale and loaded onto a truck. Each step, from weighing, label printing, labeling, to loading, requires manual assistance and verification.

[0006] The inventory management of lead stacks requires data sharing with the upper-level management system. The traditional approach is to manually upload information and print documents. Summary of the Invention

[0007] In order to overcome the problems existing in the background technology, the present invention provides an intelligent truss transfer system and transfer method for lead stacks off-line, which can realize the intelligent off-line transfer of lead stacks and automatic storage of weighing and metering data in the upper computer management system. Then the offline truss transfers the lead stacks to the transfer RGV for storage, realizing point-to-point transfer of lead stacks, replacing traditional manual forklift and overhead crane operations, replacing manpower, improving the degree of automation, avoiding the risk of cross-operation of equipment and manual labor, and greatly reducing the investment in labor costs.

[0008] To achieve the above object, the present invention is implemented through the following technical solutions: The intelligent truss transfer system for lead stacks off-line includes an off-line truss, a ground check scale and a transfer RGV; One end of the offline truss is vertically connected to the top of the lead stack production line, and the other end is connected to the top of the running track of the transfer RGV. The ground check scale is set just below the middle of the truss. The ground check scale is composed of two stacked flat platform scales: The track of the transfer RGV is installed on the ground, perpendicular to the offline truss and parallel to the lead stack production line.

[0009] Furthermore, a trolley that can run along the high-altitude track of the truss is provided on the offline truss. The trolley has a telescopic rod that can be extended up and down, and a clamp is connected below the telescopic rod.

[0010] Furthermore, the clamp realizes the opening and closing of the clamping jaws by extending and retracting two cylinders installed opposite to each other at the tail ends.

[0011] Furthermore, the ground calibration scale is used, and the upper scale directly weighs the lead pile, and the lower scale removes the tare weight of the upper scale and weighs the lead pile indirectly.

[0012] Furthermore, the intelligent truss transfer system for lead stack offline also includes a control unit, which includes a controller and monitoring equipment connected to the controller installed on the lead stack production line, offline truss, and transfer RGV, and the monitoring equipment includes a proximity switch, an encoder, and a photoelectric sensor.

[0013] Furthermore, the encoder is installed on the motor shaft of the lead stack production line, the drive motor shaft of the offline truss, the drive motor shaft of the trolley, the winch motor shaft of the telescopic rod, and the transfer RGV drive motor shaft; the photoelectric switch is installed at the conveying tail end of the lead stack production line and the ground calibration scale.

[0014] The intelligent truss transfer method for lead stacks off the production line is applicable to the above-mentioned system. Specifically, the lead stack production line continuously transports lead stacks to the end of the lead stack production line according to the set conveying rhythm. When the lead stack reaches the tail end of the lead stack production line, the photoelectric switch detects the lead stack arrival signal and sends the signal to the PLC of the lead stack production line. The PLC of the lead stack production line transmits the arrival signal to the PLC of the truss system through the relay. The truss receives the lead stack arrival signal, and the clamp clamps the lead stack in place and transports it to the ground calibration scale.

[0015] Furthermore, the lead stack clamped by the clamp is placed on the ground calibration scale for weighing. The two scales weigh the lead stack at the same time, and the weighing errors of the two scales are set. When the weighing error is within the allowable range, the weighing is qualified, realizing the mutual calibration function of the two scales.

[0016] Beneficial effects of the present invention: The present invention uses an offline truss to replace the traditional manual forklift or overhead crane to lift the lead stacks into the warehouse. At the same time, before the lead stacks are put into the warehouse, the weight of each lead stack is weighed by a ground calibration scale arranged under the truss, and the weight can be directly stored in the warehouse management system, and no further weighing is required during the loading process.

[0017] By setting up a ground calibration scale consisting of two stacked flat platform scales, the weighing calibration function is realized, making the weighing data more accurate.

[0018] Through the coordination of the offline truss and the transfer RGV, point-to-point transfer of lead stacks is achieved, replacing the traditional manual forklift and overhead crane operation, replacing manpower, improving the degree of automation, avoiding the risk of cross-operation between equipment and manual labor, and significantly reducing the investment in labor costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a system schematic diagram of the present invention; Figure 2 It is a front view of the downline truss device of the present invention; Figure 3 A top view of the downline truss device of the present invention; Figure 4 It is a side view of the downline truss device of the present invention; Figure 5 This is a structural diagram of a clamp for the offline truss device of the present invention; Figure 6 Schematic diagram of the position relationship between the offline truss and the transfer RGV of the present invention; Figure 7 It is a schematic diagram of the positions of two planar platform scales of the present invention; Figure 8 This is a diagram showing the state of the clamp of the present invention lifting a weight; Remark: Figure 1 The arrows in the figure represent the conveying direction of the lead stack; In the figure: 1-offline truss, 2-ground calibration scale; 3-transfer RGV; 4-RGV track; 5-weight, 6-trolley, 7-telescopic rod, 8-clamp, 9-frame track, 10-winch, 11-running wheel A, 12-telescopic cylinder, 13-running wheel B, 14-lead stack production line, 15-lead stack, 16-gripper. DETAILED DESCRIPTION

[0020] In order to make the purpose, technical solution and beneficial effects of the present invention more clear, the technical solution of the present invention will be described in detail below. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, other embodiments obtained by those skilled in the art without making creative efforts shall fall within the scope of protection of the present invention.

[0021] In order to illustrate the present invention more clearly, the following examples are given to illustrate it in detail. Example

[0022] The original manual forklift or overhead crane lifting method for lead stacks off the production line has a high degree of manual participation and the cross-operation of equipment and personnel has a high risk of personal injury; at the same time, the lead stacks are weighed when they are out of the warehouse, loaded and shipped, which takes up the delivery time; when loading, the loading weight of the truck is matched according to the current weight of the lead stack, and the manual calculation is relatively complicated; manual loading uses forklifts or overhead cranes for lifting, and requires the cooperation of multiple people such as hoists, labelers, and unloaders, resulting in a large number of personnel and serious cross-operation.

[0023] In combination with the actual needs of lead stack production and shipping site and the characteristics of the production process, this truss device system for intelligent transfer of lead stacks off the production line is designed. The intelligent truss automatically clamps the lead stacks from the production line and takes them off the production line. At the same time, the lead stacks are weighed in advance, and then the RGV transports the lead stacks to the warehouse for storage. The main design solutions are as follows: Figure 1 shown.

[0024] The intelligent truss transfer system for lead stacks off-line comprises an off-line truss device, a ground check scale and a transfer RGV.

[0025] The transfer RGV's track runs parallel to the lead stack production line. One end of the downline truss spans vertically above the lead stack production line, while the other end spans vertically above the transfer RGV's track. A ground-level scale is located directly below the center of the downline truss. The downline truss transports lead stacks from the lead stack production line to the transfer RGV. The transfer RGV then transports the stacks to storage, where they are weighed by the ground-level scale.

[0026] Photoelectric switches are installed at the tail end of the lead stack production line and on the ground verification scale. When the lead stack is transported to the tail end of the lead stack production line and directly below the offline truss, the photoelectric switch detects the lead stack in place signal and sends the signal to the lead stack production line PLC. At the same time, the lead stack production line PLC transmits the lead stack in place signal through the relay to the PLC of the truss system. The truss system receives the lead stack in place signal, runs the fixture to clamp the lead stack in place and transports it to the ground verification scale.

[0027] The photoelectric switch detects the arrival signal of the lead stack at the ground check scale and sends the signal to the PLC of the truss system. The truss system operates the fixture to place the lead stack on the ground check scale. When the weight of the lead stack on the ground check scale is stable, the weight data of the lead stack is obtained and the weight data is transmitted to the warehouse management system WMS. The ground check scale outputs a weighing completion signal to the PLC of the truss system. After receiving the weighing completion signal output by the ground check scale, the PLC of the truss system sends a loading signal to its own control system, controls the fixture to descend, clamps the lead stack, and then rises. Then, the offline truss loads the lead stack and runs it to the transfer RGV loading platform directly below it. After loading is completed, the offline truss sends a completion signal to the controller. After receiving the loading completion signal, the transfer RGV runs along the track to the warehousing conveyor line. The RGV platform refers to the flat loading position on the top of the RGV for carrying goods.

[0028] The lead stack production line clamping point, calibration scale table, and RGV table are all consistent with the longitudinal center line of the fixture.

[0029] The off-line truss has a signal interlocking function with the lead stack production line and the transfer RGV. When a lead stack reaches its designated position on the lead stack production line conveyor, the production line PLC sends a signal indicating that the stack has arrived. The off-line truss fixture then grabs the stack and unloads it within the next production line's conveyor cycle time (before the next stack reaches directly below the off-line truss). Failure to do so will cause production line congestion. When the off-line truss picks up the stack from the ground-level calibration scale and loads it onto the transfer RGV, the RGV's PLC transmits a signal indicating that the stack has reached its designated position below the truss via the host computer to the truss PLC. This ensures that the RGV is in the correct position when the off-line truss loads the stack onto the RGV table.

[0030] The lead stack production line is equipped with photoelectric sensors to monitor the conveying status of the lead stack and determine whether there is lead stack blockage, conveying abnormality, etc. If an abnormality is detected, the system can be adjusted or shut down in time to avoid accidents.

[0031] Photoelectric sensors are installed on the edge of the RGV loading platform to detect whether the lead stack is fully loaded or unloaded, ensuring the accuracy of the lead stack during the transfer and handover process. If the lead stack is not detected to be correctly loaded, the RGV will not start to prevent the lead stack from falling and ensure the continuity of the system's automated operation. Offline truss device such as Figure 2 、 Figure 3 、 Figure 4 As shown, it is supported by 6 columns, with a frame and track on the top, racks on the sides of the frame, and a trolley on the lower line truss that can run along the high-altitude track of the truss. The trolley is equipped with gears that match the track racks. The trolley achieves precise positioning of the running direction through gear rack transmission.

[0032] like Figure 4 As shown, the trolley is equipped with a telescopic rod that can be extended and retracted up and down. The telescopic rod is raised and lowered by a winch. The clamp is connected to the bottom of the telescopic rod. The winch installed on the top of the trolley drives the telescopic rod to be raised and lowered, thereby realizing the lifting and lowering of the clamp. Figure 5 As shown, the clamp includes a frame, wherein the left and right frames are frame rails with rails. The upper end of the "L"-shaped clamp is provided with a running wheel A that can move along the frame rail. The opening and closing of the clamp is completed by a set of cylinders installed under the clamp frame. The tails of the two cylinders are installed relative to each other, and the ends of the telescopic rods of the cylinders are connected to the clamps. The running wheel A is driven back and forth on the frame rail by the extension and retraction of the cylinders to realize the opening and closing of the clamp. The two clamps rely on four proximity switches to detect whether the clamps on both sides are extended and retracted into place. The lower end of the "L"-shaped clamp realizes the clamping function by hooking the bottom step part of the lead pile. Running wheels B are provided on both sides of the clamp, which are used to open quickly and effortlessly through the rolling friction of the running wheel B when the lead pile is parked on the ground and the clamp is stuck.

[0033] Encoders are installed on the motor shafts of the lead stack production line, the drive motor shafts of the off-line truss, the trolley, the telescopic boom winch motor, and the transfer RGV. By precisely detecting the number of motor revolutions and angles, the encoders calculate the displacement and speed of the off-line truss, trolley, telescopic boom, and RGV. This provides the control unit with precise position information, enabling the system to achieve precise positioning and speed control.

[0034] like Figure 6 As shown, the transfer RGV track runs parallel to the lead stack production line. The RGV can run back and forth on the track, transporting lead stacks from the truss line to the storage area for storage. The RGV's loading platform is a chain conveyor. When the lead stack is placed on the grab handle under the truss, the loading platform chain conveyor must be stationary. After the RGV receives the lead stack, it runs to the storage area for storage.

[0035] like Figure 7As shown, the floor scale is composed of two sets of scales stacked together. The top scale can directly read the weight of the lead stack, and the bottom scale can indirectly read the weight of the lead stack after removing the tare weight of the top scale. Under normal circumstances, the readings of the two sets of scales should be consistent; if there is a certain allowable weighing value error, it can also be regarded as a qualified weight product. The two sets of stacked scales can check each other's readings. If the error is too large, it means that one of the scales needs to be calibrated or has a fault. At the same time, calibration weights are set at a fixed position near the scale. Before each shift of production, the scale is calibrated by manually clamping the weights through the offline truss, such as Figure 8 Shown are the weights and the state when lifting the weights.

[0036] Finally, it should be noted that the above preferred embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail through the above preferred embodiments, those skilled in the art should understand that various changes can be made in form and details without departing from the scope defined by the claims of the present invention.

Claims

1. An intelligent truss transfer system for lead stacking off-line, characterized in that: Including offline trusses, ground check scales and transfer RGVs; One end of the offline truss is vertically connected to the top of the lead stack production line, and the other end is connected to the top of the running track of the transfer RGV. The ground check scale is set just below the middle of the truss. The ground check scale is composed of two stacked flat platform scales: The track of the transfer RGV is installed on the ground, perpendicular to the offline truss and parallel to the lead stack production line.

2. The system according to claim 1, wherein: The downline truss is provided with a trolley that can run along the truss's high-altitude track. The trolley has a telescopic rod that can be extended up and down, and a clamp is connected below the telescopic rod. The clamp realizes the opening and closing action of the clamp by extending and retracting two cylinders installed oppositely at the tail.

3. The system according to claim 1, wherein: The ground check scale is used in which the upper scale directly weighs the lead pile, and the lower scale removes the tare weight of the upper scale and weighs the lead pile indirectly.

4. The system according to any one of claims 1 to 3, characterized in that It also includes a control unit, which includes a controller and monitoring equipment connected to the controller and installed on the lead stack production line, offline truss, and transfer RGV. The monitoring equipment includes a proximity switch, an encoder, and a photoelectric sensor.

5. The system according to claim 4, wherein: The encoder is installed on the motor shaft of the lead stack production line, the drive motor shaft of the offline truss, the drive motor shaft of the trolley, the winch motor shaft of the telescopic rod, and the transfer RGV drive motor shaft; the photoelectric switch is installed at the conveying tail end of the lead stack production line and the ground calibration scale.

6. An intelligent truss transfer method for lead stacks off-line, applicable to the system according to claim 4, characterized in that: The lead stack production line continuously transports lead stacks to the end of the lead stack production line according to the set conveying rhythm. When the lead stack reaches the end of the lead stack production line, the photoelectric switch detects the lead stack arrival signal and sends the signal to the PLC of the lead stack production line. The lead stack production line PLC transmits the arrival signal to the PLC of the truss system through the relay. The truss receives the lead stack arrival signal, and the fixture clamps the lead stack in place and transports it to the ground calibration scale.

7. The intelligent truss transport method according to claim 5, characterized in that: The photoelectric switch detects the arrival of the lead stack and transmits the information to the PLC of the truss system. The PLC of the truss system runs the fixture to place the lead stack on the ground calibration scale for weighing. The two scales weigh the lead stack at the same time and set the weighing error of the two scales. When the weighing error is within the allowable range, the weighing is qualified, realizing the mutual calibration function of the two scales.

8. The intelligent truss transport method according to claim 5, characterized in that: After the lead stack is weighed on the ground calibration scale, the PLC-operated fixture of the truss system picks up the lead stack from the ground calibration scale and sends it to the transfer RGV platform running just below the truss. The RGV carries the lead stack to the next link for storage; the RGV platform refers to the flat loading position on the top of the RGV for carrying goods.

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