Full-automatic packaging method and system for injection molding machine

Abstract

The invention relates to a full-automatic packaging method and system for an injection molding machine, and relates to the field of automation control, and the full-automatic packaging method comprises the steps that equipment starting signals and product boxing information are collected; obtaining product label information according to the product boxing information; when the equipment starting signal is consistent with a preset equipment operation signal, collecting current label information; if the current label information is consistent with the product label information, obtaining a specific boxed object based on the current label information; according to the specific boxed object, object grabbing parameters and a box body model are generated, and based on the object grabbing parameters, a preset truss manipulator is controlled to clamp the specific boxed object into a preset object placing area; and in the object containing area, a preset boxing mechanical arm is controlled to clamp the specific boxed object into a box body corresponding to the box body model, and therefore object packaging is completed. The device has the effect of improving the overall production efficiency.

Description

Technical Field

[0001] This invention relates to the field of automation control, and in particular to a fully automatic packaging method and system for injection molding machines. Background Technology

[0002] The fully automated packaging method for injection molding machines refers to a fully automated operation method that, after plastic products are produced by injection molding machines, integrates automated equipment, control systems, and corresponding mechanical actuators to achieve a series of processes from taking out, sorting, testing, counting, packaging (such as bagging, boxing, and wrapping) to finished product palletizing.

[0003] Currently, in the field of fully automated packaging for injection molding machines, existing technologies have achieved a certain degree of automation in the operation process. For example, visual scanning technology is commonly used in the product identification process. High-definition cameras are used to capture images of the injection-molded products, and image processing algorithms are combined to analyze and judge information such as the product's model, specifications, and appearance, thereby completing the product classification and identification.

[0004] When product recognition relies on visual scanning, it involves multiple steps such as image acquisition, transmission, and algorithm analysis. During this process, the main line conveyor needs to reduce its operating speed or even pause briefly to match the recognition rhythm in order to ensure recognition accuracy. This directly limits the efficiency of product flow on the main line. When multiple injection molding machines simultaneously convey products to the main line, delays in the recognition process can easily cause products to accumulate on the main line, leading to congestion and reducing overall production efficiency. This needs to be improved. Summary of the Invention

[0005] To improve overall production efficiency, this invention provides a fully automatic packaging method and system for injection molding machines.

[0006] In a first aspect, the present invention provides a fully automatic packaging method for injection molding machines, employing the following technical solution: A fully automatic packaging method for injection molding machines, comprising: Collect equipment start-up signals and product packing information; Product label information is derived from product packing information; When the device start signal matches the preset device operation signal, collect the current tag information; If the current label information matches the product label information, the specific packaged items are obtained based on the current label information; Based on the specific items to be packed, generate the item gripping parameters and the box model, and based on the item gripping parameters, control the preset gantry robot to clamp the specific items to the preset item placement area; In the object placement area, the preset packing robot is controlled to clamp the specific object into the box corresponding to the box model, thereby completing the object packaging.

[0007] By adopting the above technical solution, product label information is extracted as a matching benchmark by collecting equipment start signals and product packing information. When the equipment is running, the current label information is collected and compared with the product label information to quickly confirm the specifications and model of the product to be packaged. For products with matching labels, the system directly determines the specific packing item based on the label information, generates the corresponding item grasping parameters and box model, controls the gantry robot to accurately clamp the product to the placement area, and then the packing robot completes the packing operation. This eliminates the step of slowing down or stopping the main line conveyor due to waiting for visual recognition. Even if multiple injection molding machines simultaneously feed products to the main line, product classification and packaging instructions can be quickly completed through label matching, reducing the risk of main line congestion caused by recognition delays and improving the overall production efficiency of fully automatic packaging of injection molding machines.

[0008] Optional, also includes: Quantity of items in the collection box; The maximum packing quantity is determined based on the container model and the specific items to be packed. When the number of items in the box is the same as the maximum packing quantity, report a box full notification and collect the box number. Based on the full box number and the preset box placement area layout, generate the robot arm packing parameters; The packing robot is controlled to pack boxes according to the robot packing parameters, and the boxes corresponding to the full box numbers are transported to the preset finished product temporary storage area.

[0009] Optionally, it also includes a step following the determination of the maximum packing quantity based on the container model and specific items to be packed: The remaining number of boxes is calculated based on the number of items inside the box and the maximum number of boxes that can be packed. When the remaining quantity of boxes equals the preset replenishment warning value, the replenishment box model is matched according to the box model, and the required replenishment box number is collected. The location of the required supplementary boxes is known based on the supplementary box number and the preset box placement area layout. Responding to demand, replenish the box location to match the replacement buffer location; When the remaining number of boxes is 0, a box full warning is reported, and the preset empty box grabbing robot is controlled to move the box from the replacement buffer position to the position where the box needs to be replenished.

[0010] Optional, product line control methods may also be included: Collect product location information; Based on product location information, the current area of ​​the product can be determined; When the product falls into the preset collision area, the operation of the preset transfer robot is stopped, and the product outflow information of the collision area is collected. When the product outflow information matches the preset outflow collision area information, restart the transfer robot operation; When the product does not fall into the preset collision area in the current area, collect the number of products in the current area; The production line control instructions are generated based on the number of products in the region, and the production line is controlled based on the production line control instructions.

[0011] Optional, also includes: Acquire empty box image information; Image recognition is performed on the interior of the empty box from the image information of the empty box to obtain the posture of the inner flap; Determine if the inner flap posture is the preset inner flap tilt posture; If the inner flap is not in the tilted-up position, the inner flap of the empty box is deemed to be in a qualified position. If the inner flap is in a tilted-up position, then the posture will be corrected using the preset inner flap correction method.

[0012] Optionally, the inner flap correction method includes: The position of the inner flap is determined based on the empty box image information and the preset inner flap features; The vibration location is determined based on the position of the inner flap and the housing model. The preset vibration device is controlled to vibrate at a preset vibration frequency at the vibration position, and vibration image information is acquired. Image recognition of the interior of the empty box is performed from vibration image information to obtain the vibration posture of the inner flap. If the vibration posture of the inner flap is not the tilted posture, report the completion of flap correction.

[0013] Optional, also includes: If the vibration posture of the inner flap is the tilted posture, the angle of the inner flap is identified from the vibration image information to obtain the actual tilting angle. The tilt angle of the box is obtained based on the actual tilt angle. The initial product placement position is determined by combining the tilt position of the inner flap and the tilt angle of the box. The preset box tilting device is controlled to tilt the empty box at a tilt angle value, while the packing robot is controlled to pack the product at the initial product placement position and collect placement image information. Based on the placement image information, determine whether the inner flap has returned to the preset qualified posture; If the inner flap has been returned to the correct position, the box tilting device will reset the empty box to a horizontal position to continue the subsequent packing operation. If the inner flap does not return to the correct position, pack the product using the preset tilting packing method.

[0014] Optionally, the tilting packing method includes: When the inner flap does not return to the qualified posture, the product angle value is obtained based on the placement image information and preset product characteristics. The angle adjustment value is obtained based on the product angle value and the preset horizontal angle value; The secondary product placement position is generated based on the angle adjustment value, the box tilt angle value, and the initial product placement position. The control box tilting device dynamically corrects the box angle according to the angle adjustment value, so that the product is placed horizontally; Control the packing robot to pack products at the secondary product placement position and update the placement image information.

[0015] Optionally, a method for adjusting the angle of the cabinet when placing the product is also included: When the packing robot is packing products, it captures real-time images of the product placement. The real-time angle value of the product is obtained based on the real-time placement image and product characteristics. The real-time angle adjustment value is obtained by combining the product's real-time angle value and horizontal angle value. The current angle value of the box is obtained based on the box tilt angle value and the angle adjustment value; The maximum real-time adjustment value is obtained by responding to the current angle value of the enclosure and the preset horizontal angle value of the enclosure; The control box tilting device adjusts the box angle according to the real-time angle adjustment value until the real-time angle adjustment value matches the maximum real-time adjustment value, at which point the angle adjustment stops.

[0016] Secondly, this application provides a fully automatic packaging system for injection molding machines, which adopts the following technical solution: A fully automatic packaging system for injection molding machines, comprising: The data acquisition module is used to collect equipment start-up signals, product packing information, and current label information; The memory is used to store the program that implements any of the above-mentioned fully automatic packaging methods for injection molding machines; The processor is used to load and execute programs stored in memory.

[0017] In summary, this application includes at least one of the following beneficial technical effects: 1. By collecting equipment start signals and product packing information, product label information is extracted as a matching benchmark. When the equipment is running, the current label information is collected and compared with the product label information to quickly confirm the specifications and model of the product to be packaged. For products with matching labels, the system directly determines the specific packing item based on the label information, generates the corresponding item gripping parameters and box model, controls the gantry robot to accurately grip the product to the placement area, and then the packing robot completes the packing operation. This eliminates the step of slowing down or stopping the main line conveyor due to waiting for visual recognition. Even if multiple injection molding machines simultaneously feed products to the main line, product classification and packaging instructions can be quickly completed through label matching, reducing the risk of main line congestion caused by recognition delay and improving the overall production efficiency of fully automatic packaging of injection molding machines. 2. By locating the position of the tilted inner flap using image recognition and determining the optimal vibration point based on the box model, the vibration device is controlled to vibrate at an appropriate frequency. The inertial force generated by the vibration is used to reset the tilted flap. After vibration, the correction effect is verified again using image recognition to ensure the flap's posture is correct. This method is gentler than mechanical pressing correction, especially suitable for fragile materials such as cardboard boxes. It can quickly resolve the flap tilting problem while avoiding box deformation, ensuring a smooth subsequent packing process. 3. When the inner flap continues to tilt, the system uses image recognition to identify the product angle and calculates the additional angle value that the box needs to be adjusted to keep the product in a horizontal position in the tilted box. This not only uses the product's gravity to suppress the tilted flap, but also avoids unstable stacking caused by the product being placed at an angle, laying the foundation for subsequent sealing and palletizing, and improving the overall packaging quality. Attached Figure Description

[0018] Figure 1 This is a flowchart of a fully automated packaging method for injection molding machines. Figure 2 This is a flowchart of the inner flap correction method; Figure 3 This is a flowchart of the tilted packing method; Figure 4 This is a flowchart illustrating the method for adjusting the angle of the box when placing the product. Detailed Implementation

[0019] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0020] Reference Figure 1 This application discloses a fully automatic packaging method for injection molding machines, including the following steps: S1: Collects equipment start-up signals and product packing information.

[0021] The equipment start signal is a signal used to determine whether the fully automated packaging production line of the injection molding machine has started. The equipment start signal is acquired through a preset signal acquisition device (such as a button sensor, limit switch, or signal interface connected to the injection molding machine control system).

[0022] Product packing information refers to information including the type, specifications, quantity, and packing method of the products to be packaged (such as the quantity placed on each layer and the number of stacked layers). Product packing information is obtained through pre-input by those skilled in the art.

[0023] S2: Obtain product label information based on product packing information.

[0024] Product label information refers to the specific information contained in the label used to identify basic product information, characteristics, etc. Product label information can be obtained by accessing product packaging information; the product packaging information includes the product label information.

[0025] S3: When the device start signal is consistent with the preset device operation signal, collect the current tag information.

[0026] Equipment operation signals refer to the reference signals that indicate the system has started normally and entered the operating state. Equipment operation signals are preset by those skilled in the art and will not be elaborated here.

[0027] Current label information refers to the information obtained by scanning and identifying the actual label on the product to be packaged using RFID.

[0028] When the equipment start signal and the equipment operation signal are consistent, it means that the fully automatic packaging production line of the injection molding machine has been started and is running. It is necessary to collect the current label information first for subsequent steps.

[0029] S4: If the current label information is consistent with the product label information, obtain the specific packaged items based on the current label information.

[0030] Specific packaged items refer to the actual products that need to be packaged. A pre-set product lookup table can be used to find the specific packaged items corresponding to the current label information. This table records different specific packaged items corresponding to different current label information. The comparison content in the product lookup table is formed by those skilled in the art by sequentially recording the different specific packaged items corresponding to different current label information, which will not be elaborated upon here.

[0031] If the current label information matches the product label information, it means that the actual identification of the product to be packaged matches the preset product plan identification, ensuring the accuracy of the product to be packaged, and subsequent grabbing and packing operations can be carried out.

[0032] S5: Generate object gripping parameters and box model based on the specific boxed items, and control the preset gantry robot to clamp the specific boxed items into the preset object placement area based on the object gripping parameters.

[0033] Object grasping parameters refer to the parameters used to control the grasping actions of the gantry robot, including the coordinates of the grasping point, clamping force, lifting height, and moving speed. A preset grasping lookup table can be used to look up the corresponding object grasping parameters for a specific packaged object. This table records different object grasping parameters for different specific packaged objects. The reference content in the grasping lookup table is preset and recorded by those skilled in the art based on the physical characteristics of the specific packaged object and the performance parameters of the gantry robot, and will not be elaborated upon here.

[0034] The container model refers to the specification identifier of the container used to hold specific packed items. A pre-set packing lookup table can be used to find the corresponding container model for a specific packed item. This table records the different container models corresponding to different specific packed items. The content of the packing lookup table is pre-set and recorded by those skilled in the art based on the physical parameters of the specific packed item and the specification parameters of the container, and will not be elaborated upon here.

[0035] A truss robot is an automated material handling device installed on a truss structure.

[0036] The object placement area refers to a transitional area used for temporary storage of objects to be packed, facilitating the packing robot to grasp the objects from this area for packing operations. The object placement area is predetermined by those skilled in the art and will not be elaborated upon here.

[0037] A packing robot is an automated device specifically designed to pick up items from a designated area and pack them into corresponding boxes.

[0038] S6: In the object placement area, control the preset packing robot to clamp the specific object into the box corresponding to the box model, thereby completing the object packaging.

[0039] After clamping the specific items into the designated area, the packing robot needs to be controlled to clamp the specific items into the box corresponding to the box model, thereby completing the packaging.

[0040] It also includes the following steps: S60: Number of items in the collection box.

[0041] The number of items inside the box refers to the number of specific items currently packed inside the box. This number is obtained through a preset infrared beam sensor. The method of using an infrared beam sensor to collect the number of items inside the box is common knowledge in this field and will not be elaborated upon here.

[0042] S61: Determine the maximum packing quantity based on the container model and specific items to be packed.

[0043] The maximum packing quantity refers to the maximum number of items that a single box can hold. The maximum packing quantity is calculated using a spatial arrangement algorithm, combining the box model's specifications with the physical parameters of the specific items to be packed. This spatial arrangement algorithm is common knowledge in the field and will not be elaborated upon here.

[0044] S62: When the number of items in the box is the same as the maximum packing quantity, report a box full notification and collect the box number.

[0045] The full-box number refers to the number of the box that has reached the maximum packing quantity. In this embodiment, each box will be assigned a corresponding number, and the specific numbering will be predetermined by those skilled in the art and will not be described in detail here.

[0046] The box number is obtained through a pre-set RFID reader. When the number of items in the box reaches the maximum packing quantity, the RFID reader identifies the number carrier on the box, reads and records the corresponding number, which is the full box number.

[0047] When the number of items in the box matches the maximum packing quantity, it means that the box can no longer hold any more products. A box full notification should be reported, and the box number should be collected.

[0048] S63: Generate robot packing parameters based on the full box number and the preset box placement area layout.

[0049] The layout of the container placement area refers to the spatial distribution planning of the containers in the product packing area, including the coordinates of each location and the functional division of the area. The layout of the container placement area is predetermined by those skilled in the art and will not be elaborated here.

[0050] The packing parameters for a robotic arm refer to the parameters used to guide the adjustment of the packing robot's work path when a box is full. By knowing the box number of the full box, the specific position of the full box in the box placement area is located. Then, this position is removed from the original work path plan (pre-set by those skilled in the art, which will not be elaborated here) because the box no longer needs to be packed. Combined with the position coordinates of the remaining unfilled boxes in the layout, the movement path, work sequence, and alignment accuracy of the packing robot are re-planned to obtain the robotic arm packing parameters.

[0051] S64: Control the packing robot to pack boxes according to the robot packing parameters, and transport the boxes corresponding to the full box numbers to the preset finished product temporary storage area.

[0052] The finished product temporary storage area refers to the area used for the temporary storage of finished product boxes that have been packed. The finished product temporary storage area is set in advance by those skilled in the art and will not be described in detail here.

[0053] While controlling the packing robot to pack other boxes according to the robot packing parameters, the boxes corresponding to the full box numbers need to be transported to the finished product temporary storage area through the preset full box conveyor line for subsequent steps.

[0054] A full-case conveyor line is a conveyor line used to transport full cases to the finished product storage area. The full-case conveyor line is located below the packing area.

[0055] It also includes steps following the determination of the maximum packing quantity based on the container model and specific items to be packed: S610: Calculate the remaining packing quantity based on the number of items in the box and the maximum packing quantity.

[0056] The remaining packing quantity refers to the number of items that can still be packed into the box after subtracting the current number of items in the box from the maximum packing quantity.

[0057] S611: When the remaining quantity of boxes is equal to the preset replenishment warning value, match the replenishment box model according to the box model and collect the required replenishment box number.

[0058] The replenishment warning value refers to the threshold of remaining container quantity that triggers the empty container replenishment mechanism. It is used to prepare empty containers in advance and avoid packing interruptions. The replenishment warning value is preset by those skilled in the art and will not be elaborated here.

[0059] The supplementary container model number refers to the empty container model number that is identical to the currently packed container model number. Since the supplementary container model number must match the model number of the full container, the supplementary container model number can be obtained by knowing the container model number.

[0060] The demand replenishment container number refers to the container number whose remaining quantity equals the replenishment warning value. The demand replenishment container number is obtained through an RFID reader.

[0061] When the remaining number of boxes equals the replenishment warning value, it means that empty boxes need to be prepared in advance to replenish the box at this location and avoid packing interruption. Therefore, it is necessary to first match the model of the replenishment box and then collect the required replenishment box number for subsequent steps.

[0062] S612: Based on the required supplementary container number and the preset container placement area layout, the location of the required supplementary container is known.

[0063] The location of the supplementary container refers to the specific spatial coordinates where the supplementary empty container needs to be placed. This is achieved by first identifying the container number, then matching it against the container placement area layout. This layout records the spatial coordinates of each container number. By locating the corresponding entry for each supplementary container number in the layout, the specific spatial coordinates of the empty container to be placed—that is, the location of the supplementary container—can be obtained.

[0064] S613: Responds to demand by replenishing the housing position to match the replacement buffer position.

[0065] A replacement buffer location refers to a transitional location used for temporarily storing spare empty containers. The replacement buffer location is determined based on the location of the required replenishment containers using preset location matching rules. The system pre-stores information on the transitional locations of spare empty containers corresponding to each required replenishment container location. Once the required replenishment container location is obtained, the replacement buffer location for temporarily storing spare empty containers can be matched by calling this preset correspondence. This correspondence is preset by those skilled in the art based on the spatial planning of the container placement area and the requirements for empty container replenishment efficiency, and will not be elaborated upon here.

[0066] S614: When the remaining number of boxes is 0, report a box full warning and control the preset empty box grabbing robot to move the box from the replacement buffer position to the position of the box to be replenished.

[0067] An empty container grabbing robot is an automated device specifically designed for grabbing and moving empty containers.

[0068] When the remaining number of boxes is 0, it means that the box is full and a box full warning needs to be reported. At the same time, S62 to S64 are executed, and the empty box grabbing robot is controlled to move the box from the replacement buffer position to the position of the box that needs to be replenished.

[0069] It also includes product line control methods: S30: Collect product location information.

[0070] Product location information refers to the coordinate data of the product to be packaged on the production line, which is collected in real time by photoelectric sensors.

[0071] S31: Know the current area of ​​the product based on the product location information.

[0072] The current product area refers to the segment area (e.g., 1s, 2s, 3s, etc.) on the production line where the product is currently located. The current product area is obtained by matching the product's location information to different regions. The production line is pre-divided into multiple segments (e.g., 1s, 2s, 3s, etc.), each corresponding to a specific spatial coordinate range. This region division information is pre-stored in the system. When product location information (i.e., the product's specific coordinates on the production line) is collected, these coordinates are compared with the coordinate ranges of each segment area to determine the segment area to which the product's coordinates belong. This segment area is the product's current area. The specific range and identifiers of the region divisions (e.g., 1s, 2s) are pre-defined by those skilled in the art based on production line length, operational requirements, etc., and will not be elaborated upon here.

[0073] S32: When the product falls into the preset collision area, stop the operation of the preset transfer robot and collect the product outflow information from the collision area.

[0074] The collision zone refers to the area on the production line where a product may collide with the transfer robot. The collision zone is predetermined by those skilled in the art and will not be elaborated upon here.

[0075] A transfer robot is an automated device used to transfer products between different areas of an assembly line.

[0076] Product outflow information refers to the status information reflecting whether a product has left the collision area. This information is collected by a photoelectric sensor. The photoelectric sensor is installed at the exit boundary of the collision area. When a product leaves the collision area through the exit, the sensor is triggered and generates a corresponding signal, which indicates that the product has left the collision area. If the product has not left the collision area, the sensor remains in its initial detection state (e.g., continuously blocked), thus distinguishing whether the product has left the collision area. The specific installation location of the sensor and the signal judgment logic are determined by those skilled in the art based on the range of the collision area and will not be elaborated here.

[0077] When a product falls into the collision zone, it indicates that the transfer robot will collide with the product if it continues to operate. Therefore, the transfer robot must be stopped, and the product outflow information from the collision zone should be collected for subsequent steps.

[0078] S320: When the product outflow information matches the preset outflow collision area information, restart the transfer robot operation.

[0079] The exit collision zone information refers to the baseline state information of a product successfully leaving the collision zone. This exit collision zone information is preset by those skilled in the art and will not be elaborated upon here.

[0080] When the product outflow information matches the outflow collision area information, it indicates that the product has successfully left the collision area, and the transfer robot needs to be restarted.

[0081] S33: When the current area of ​​the product does not fall into the preset collision area, collect the number of products in the current area of ​​the product.

[0082] The number of products in a region refers to the total number of products within the region where the current product is located. The number of products in a region is obtained by counting using photoelectric sensors.

[0083] If the product does not fall into the collision zone in its current area, it means that the transfer robot will continue to operate without colliding with the product. It is necessary to first collect the number of products in the current area for subsequent steps.

[0084] S330: Generates production line control instructions based on the number of products in the region, and controls the operation of the production line based on the production line control instructions.

[0085] Assembly line control commands are instructions generated based on the quantity of products in a region, used to control the operation of the assembly line, such as start, stop, and speed adjustment, to avoid product congestion in that region. Assembly line control commands are obtained by matching them against a pre-set assembly line control database. This database stores specific matching rules between different product quantities in different regions and their corresponding assembly line control commands, including start, stop, speed adjustment, and stop / stop operation commands and execution logic set for different quantity thresholds.

[0086] For example, if there is only one product in the area, the product gap barrier is kept open to intercept subsequent products. The barrier is closed after the transfer robot completes the current product grabbing.

[0087] If the number of products in the area reaches 2, the barrier will be controlled to allow the next product to pass through after the previous product has left the current area.

[0088] If the number of products in the area reaches 3, the production line will be suspended until the transfer robot completes the product grabbing and the number in the area drops below 3, at which point the production line will resume operation.

[0089] The production line control database is pre-set by those skilled in the art and will not be elaborated here.

[0090] It also includes the following steps: S7: Acquire image information of empty boxes.

[0091] Empty container image information refers to images of empty containers to be used, captured by a camera.

[0092] S70: Perform image recognition on the interior of the empty box from the image information of the empty box to obtain the posture of the inner flap.

[0093] The inner flap posture refers to the spatial state (such as lying flat, tilted, or leaning) of the flap inside an empty container (the inner cover of the container's folding structure). Image recognition technology can be used to identify the interior of an empty container from its image information to determine the inner flap posture. Image recognition technology is common knowledge in this field and will not be elaborated upon here.

[0094] S71: Determine whether the inner flap posture is the preset inner flap tilt posture.

[0095] The tilted-up posture of the inner flap refers to the state when the inner flap of the empty carton is tilted upwards. The threshold for judging the tilted-up posture of the inner flap is set in advance by those skilled in the art, and will not be elaborated here.

[0096] By determining whether the inner flap is tilted upwards, we can ascertain whether the inner flap of the empty box is obstructing the loading of specific items. This allows us to determine whether the posture of the inner flap needs to be corrected to ensure the smooth progress of subsequent packing operations.

[0097] S72: If the inner flap is not in the tilted-up position, the inner flap of the empty box is deemed to be in the correct position.

[0098] If the inner flap is not tilted up, it means that the inner flap is in a flat position and its position and angle will not obstruct the placement of the specific items in the box. In this case, the inner flap of the empty box can be directly judged to be in a qualified position and can be used for subsequent packing operations without additional correction.

[0099] S73: If the inner flap is in an inverted position, then the posture is corrected using the preset inner flap correction method.

[0100] The inner flap correction method refers to the operational procedure used to adjust the inner flap to a qualified state when its posture does not conform to the tilted-up posture. Specific inner flap correction methods will be detailed in subsequent sections S730 to S7355, and will not be elaborated upon here.

[0101] If the inner flap is tilted upwards, it indicates that the state of the inner flap has become a potential obstacle to the packing operation. Therefore, it is necessary to activate the inner flap correction method to adjust its posture until the inner flap is restored to a qualified state to ensure the smoothness of the packing process.

[0102] Reference Figure 2 The inner flap correction method includes the following steps: S730: Determines the tilt position of the inner flap based on empty box image information and preset inner flap features.

[0103] The inner flap feature refers to the external outline features of the inner flap. The inner flap feature is predetermined by those skilled in the art and will not be described in detail here.

[0104] The inner flap lift position refers to the specific spatial location where the inner flap is actually lifted. By using image recognition technology to analyze the interior of an empty box in an image, areas matching the characteristics of the inner flap can be identified, thereby pinpointing the specific spatial location where the inner flap is actually lifted, i.e., the inner flap lift position.

[0105] S731: The vibration location is determined based on the position of the inner flap and the housing model.

[0106] The vibration location refers to the specific position where the vibration device acts on the enclosure. By understanding the enclosure model, we can know its corresponding internal structural layout (such as the connection position between the inner flap and the side wall of the enclosure, the dimensional proportions of each side of the enclosure, etc.). Combined with the position of the inner flap, we can locate the external area of ​​the enclosure that can be acted upon, which is the specific position where the vibration device needs to apply vibration, i.e., the vibration location.

[0107] A vibration device is a device installed on the conveying path of an empty container that can generate vibration.

[0108] S732: Controls a preset vibration device to vibrate at a preset vibration frequency at a vibration location and acquires vibration image information.

[0109] Vibration frequency refers to the number of vibrations per unit time of a vibrating device. The vibration frequency is preset by those skilled in the art and will not be elaborated here.

[0110] Vibration image information refers to image data of an empty box captured during the operation of the vibration device. Vibration image information is obtained through camera capture.

[0111] When controlling the vibration device to vibrate at a vibration frequency to vibrate the vibration position, it is necessary to collect vibration image information for subsequent steps.

[0112] S733: Perform image recognition on the interior of the empty box from vibration image information to obtain the vibration posture of the inner cover.

[0113] The vibration attitude of the inner flap refers to the real-time state of the inner flap after vibration, which is used to determine whether the correction was successful.

[0114] The method for determining the vibration attitude of the inner cover is the same as that for S70 above, and will not be repeated here.

[0115] S734: If the vibration posture of the inner flap is not the tilted posture of the inner flap, report the completion of flap correction.

[0116] If the vibration posture of the inner cover is not the tilted posture of the inner cover, it means that the tilting correction of the inner cover has been completed, and the completion of the cover correction can be reported.

[0117] It also includes the following steps: S735: If the inner flap vibrates in a tilted-up position, the inner flap features are identified from the vibration image information to obtain the actual tilting angle.

[0118] The actual tilt angle refers to the angle at which the inner flap actually tilts up after vibration (the angle relative to the bottom of the housing). The actual tilt angle is measured from vibration image information using image recognition technology. Image measurement angles are common knowledge in this field and will not be elaborated upon here.

[0119] If the inner cover vibrates in a tilted-up position, then vibration alone cannot correct the tilting of the inner cover. The actual tilting angle must be identified first for subsequent steps.

[0120] S7350: The box tilt angle value is obtained based on the actual tilt angle.

[0121] The box tilt angle refers to the angle at which the box needs to be tilted, used to allow the inner flap to return to a proper posture under the product's gravity. A preset tilt reference table can be used to look up the box tilt angle value corresponding to the actual tilt angle. This table records the mapping relationship between different actual tilt angles and their corresponding box tilt angle values. These mapping relationships are preset by those skilled in the art based on factors such as the material and weight of the inner flap, its connection strength to the box, and the corrective effect of the product's gravity on the flap's posture. For example, when the actual tilt angle is 10°, the corresponding box tilt angle value is 15°; when the actual tilt angle is 20°, the corresponding box tilt angle value is 25°, and so on. Through this preset correspondence, a suitable box tilt angle value can be quickly matched to the actual tilt angle, ensuring that after the box is tilted, the product can effectively correct the inner flap's posture using gravity.

[0122] S7351: Combine the tilt position of the inner flap and the tilt angle of the box to obtain the initial product placement position.

[0123] The initial product placement position refers to the spatial coordinates of the product initially placed inside the box. This ensures that the product, after placement, can act on the inner flap to correct its posture. The initial product placement position is calculated using a spatial positioning algorithm, combining the spatial coordinates of the inner flap's tilted position and the box's tilt angle. This spatial positioning algorithm is common knowledge in the field and will not be elaborated upon here.

[0124] Specifically, based on the specific spatial position of the raised inner flap, combined with the spatial posture of the box after tilting at the tilt angle, the coordinates of the contact point that allows the first product to be placed accurately to act on the raised inner flap are determined. These coordinates are the initial product placement position.

[0125] S7352: Controls the preset box tilting device to tilt the empty box at a box tilting angle value, and simultaneously controls the packing robot to pack the product at the initial product placement position and collects placement image information.

[0126] A box tilting device is a device used to adjust the tilt angle of a box.

[0127] Placement image information refers to image data captured after the product is placed in the tilted box. Placement image information is obtained through camera capture.

[0128] When the box tilting device tilts the empty box at the tilt angle value, the packing robot should be controlled simultaneously to pack the product at the initial product placement position. This ensures that the product can be accurately placed on the tilted inner flap. At the same time, placement image information should be collected for subsequent steps.

[0129] S7353: Determine whether the inner flap has returned to the preset qualified posture based on the placement image information.

[0130] A qualified posture refers to the state in which the inner flap meets the packing requirements. The specific qualified posture is predetermined by those skilled in the art and will not be elaborated here.

[0131] By performing image recognition on the placement image information, the real-time posture features of the inner flap are extracted, and these features are compared with the preset qualified posture standard to determine whether the inner flap has returned to the qualified posture.

[0132] S7354: If the inner flap has been restored to the correct position, control the box tilting device to reset the empty box to a horizontal position so that subsequent packing operations can continue.

[0133] If the real-time posture characteristics of the inner flap are consistent with the qualified posture standard, it is determined that it has been restored to the qualified posture. The box tilting device needs to be controlled to reset the empty box to a horizontal state, and the subsequent boxing operation can continue.

[0134] S7355: If the inner flap does not return to the correct position, pack the product using the preset tilt packing method.

[0135] The tilting packing method refers to a packing method that dynamically adjusts the tilt angle of the box and the placement of the product when the inner flap fails to return to a satisfactory position after initial tilting. Specific details of the tilting packing method are provided in subsequent sections S73550 to S73554 and will not be repeated here.

[0136] If the real-time posture characteristics of the inner flap are inconsistent with the qualified posture standard, it is determined that it has not been restored and the product needs to be packed using the tilt packing method.

[0137] Reference Figure 3 The tilted packing method includes the following steps: S73550: When the inner flap does not return to the qualified posture, the product angle value is obtained based on the placement image information and the preset product characteristics.

[0138] The product angle value refers to the actual tilt angle of the product within the tilting box (the angle relative to the horizontal direction). The spatial orientation of the product features within the tilting box is identified from the placement image information, and then the angle between the product and the horizontal direction is calculated using a geometric algorithm; this angle is the product angle value.

[0139] If the inner flap does not return to the correct position, the product angle value must be identified first for subsequent steps.

[0140] S73551: Obtain the angle adjustment value based on the product angle value and the preset horizontal angle value.

[0141] The horizontal angle value refers to the reference angle for maintaining the product in a horizontal state. The horizontal angle value is preset by those skilled in the art and will not be elaborated here.

[0142] Angle adjustment value refers to the amount of angle adjustment required, calculated based on the difference between the product's angle value and the horizontal angle value, to keep the product horizontal when placed.

[0143] S73552: Generates secondary product placement positions based on angle adjustment values, box tilt angle values, and initial product placement positions.

[0144] The secondary product placement position refers to the new spatial coordinate position that the product needs to be placed in after dynamically adjusting the tilt angle of the box when the inner flap has not been restored to the qualified posture.

[0145] First, using the initial product placement position as the reference point, a tilted spatial coordinate system of the box is established based on the tilt angle value. Then, the reference point is transformed according to the angle adjustment value (the amount of angle adjustment required to keep the product horizontal). Through three-dimensional spatial rotation and translation calculations, the new coordinates of the product in the adjusted box coordinate system are obtained. These coordinates are the secondary product placement position.

[0146] Based on the angle adjustment value, the box tilt angle value, and the optimized product placement coordinates based on the initial product placement position, ensure that the product is placed horizontally into the box.

[0147] S73553: The control box tilting device dynamically corrects the box angle according to the angle adjustment value, so that the product is placed horizontally.

[0148] The control box tilting device dynamically corrects the box angle according to the angle adjustment value, so that subsequent products can be placed horizontally.

[0149] S73554: Controls the packing robot to pack products at the secondary product placement position and updates the placement image information.

[0150] The packing robot is controlled to pack products at the secondary product placement position, so that the second product can accurately act on the first product, thereby applying pressure to the tilted inner flap. At the same time, the placement image information needs to be updated, and S7353 to S73554 are repeated until the inner flap has returned to the qualified posture.

[0151] Reference Figure 4 It also includes methods for adjusting the angle of the box when placing the product: S73520: When the packing robot is packing products, it collects real-time images of the product placement.

[0152] Real-time product placement images refer to the image data of the product and the box captured in real time during the process of the packing robot placing the product into the box. This data is used to dynamically monitor the product's posture. Real-time product placement images are obtained through real-time capture by a camera.

[0153] When a packing robot is packing products, it needs to first capture real-time images of the product placement for subsequent steps.

[0154] S73521: Obtain the real-time angle value of the product based on the real-time placement image and product characteristics.

[0155] The real-time angle value of a product refers to its real-time tilt angle during placement. This is achieved by identifying product features from a real-time placement image, extracting the product's dynamic posture parameters from the image, and then using a real-time angle calculation algorithm to calculate the product's real-time tilt angle relative to the horizontal direction. This angle is the product's real-time angle value. The real-time angle calculation algorithm is common knowledge in this field and will not be elaborated upon here.

[0156] S73522: Combines the product's real-time angle value and horizontal angle value to obtain the real-time angle adjustment value.

[0157] The real-time angle adjustment value refers to the angle that the cabinet needs to be adjusted in real time based on the difference between the product's real-time angle value and the horizontal angle value, in order to dynamically correct the product's horizontal state.

[0158] S73523: Obtain the current angle value of the enclosure based on the enclosure tilt angle value and angle adjustment value.

[0159] The current angle value of the enclosure refers to the current tilt angle of the enclosure during real-time adjustment, which is calculated by superimposing the enclosure tilt angle value and the real-time angle adjustment value.

[0160] S73524: Responds to the current angle value of the enclosure and the preset horizontal angle value of the enclosure to obtain the maximum real-time adjustment value.

[0161] The horizontal angle value of the enclosure refers to the reference angle at which the enclosure remains horizontal. The specific horizontal angle value of the enclosure is set in advance by those skilled in the art and will not be elaborated here.

[0162] The maximum real-time adjustment value refers to the maximum allowable angle adjustment of the enclosure. It is used to prevent the enclosure from tilting excessively, causing a normally level enclosure to tilt in the opposite direction. The maximum real-time adjustment value is obtained by calculating the difference between the current angle value of the enclosure and the horizontal angle value of the enclosure.

[0163] S73525: Control the tilting device of the control box to adjust the angle of the box according to the real-time angle adjustment value until the real-time angle adjustment value is consistent with the maximum real-time adjustment value, and then stop the angle adjustment.

[0164] The control box tilting device adjusts the box angle using real-time angle adjustment values ​​until the calculated real-time angle adjustment value matches the maximum real-time adjustment value. At this point, the angle adjustment needs to be stopped, thereby completing the correction of the inner flap.

[0165] Based on the same inventive concept, embodiments of the present invention provide a fully automatic packaging system for injection molding machines, comprising: The data acquisition module is used to collect equipment start signals, product packing information, current label information, number of items in the box, full box number, required supplementary box number, product location information, product outflow information, number of products in the area, empty box image information, vibration image information, placement image information, and real-time product placement image. A memory used to store a program that implements a fully automated packaging method for an injection molding machine; The processor is used to load and execute programs stored in memory.

[0166] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0167] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiment. All technical solutions based on the concept of the present invention are within the scope of protection of the present invention. It should be noted that for those skilled in the art, various improvements and modifications that do not depart from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A fully automatic packaging method for injection molding machines, characterized in that, include: Collect equipment start-up signals and product packing information; Product label information is derived from product packing information; When the device start signal matches the preset device operation signal, collect the current tag information; If the current label information matches the product label information, the specific packaged items are obtained based on the current label information; Based on the specific items to be packed, generate the item gripping parameters and the box model, and based on the item gripping parameters, control the preset gantry robot to clamp the specific items to the preset item placement area; In the object placement area, the preset packing robot is controlled to clamp the specific object into the box corresponding to the box model, thereby completing the object packaging.

2. The fully automatic packaging method for injection molding machines according to claim 1, characterized in that, Also includes: Quantity of items in the collection box; The maximum packing quantity is determined based on the container model and the specific items to be packed. When the number of items in the box is the same as the maximum packing quantity, report a box full notification and collect the box number. Based on the full box number and the preset box placement area layout, generate the robot arm packing parameters; The packing robot is controlled to pack boxes according to the robot packing parameters, and the boxes corresponding to the full box numbers are transported to the preset finished product temporary storage area.

3. The fully automatic packaging method for injection molding machines according to claim 2, characterized in that, It also includes steps following the determination of the maximum packing quantity based on the container model and specific items to be packed: The remaining number of boxes is calculated based on the number of items inside the box and the maximum number of boxes that can be packed. When the remaining quantity of boxes equals the preset replenishment warning value, the replenishment box model is matched according to the box model, and the required replenishment box number is collected. The location of the required supplementary boxes is known based on the supplementary box number and the preset box placement area layout. Responding to demand, replenish the box location to match the replacement buffer location; When the remaining number of boxes is 0, a box full warning is reported, and the preset empty box grabbing robot is controlled to move the box from the replacement buffer position to the position where the box needs to be replenished.

4. The fully automatic packaging method for injection molding machines according to claim 1, characterized in that, It also includes product line control methods: Collect product location information; Based on product location information, the current area of ​​the product can be determined; When the product falls into the preset collision area, the preset transfer robot stops running and collects the product outflow information from the collision area. When the product outflow information matches the preset outflow collision area information, restart the transfer robot operation; When the product does not fall into the preset collision area in the current area, collect the number of products in the current area; The production line control instructions are generated based on the number of products in the region, and the production line is controlled based on the production line control instructions.

5. The fully automatic packaging method for injection molding machines according to claim 3, characterized in that, Also includes: Acquire empty box image information; Image recognition is performed on the interior of the empty box from the image information of the empty box to obtain the posture of the inner flap; Determine if the inner flap posture is the preset inner flap tilt posture; If the inner flap is not in the tilted-up position, the inner flap of the empty box is deemed to be in a qualified position. If the inner flap is in a tilted-up position, then the posture will be corrected using the preset inner flap correction method.

6. The fully automatic packaging method for injection molding machines according to claim 5, characterized in that, The inner flap correction method includes: The position of the inner flap is determined based on the empty box image information and the preset inner flap features; The vibration location is determined based on the position of the inner flap and the housing model. The preset vibration device is controlled to vibrate at a preset vibration frequency at the vibration position, and vibration image information is collected. Image recognition of the interior of the empty box is performed from vibration image information to obtain the vibration posture of the inner flap. If the vibration posture of the inner flap is not the tilted posture, report the completion of flap correction.

7. The fully automatic packaging method for injection molding machines according to claim 6, characterized in that, Also includes: If the vibration posture of the inner flap is the tilted posture, the angle of the inner flap is identified from the vibration image information to obtain the actual tilting angle. The tilt angle of the box is obtained based on the actual tilt angle. The initial product placement position is determined by combining the tilt position of the inner flap and the tilt angle of the box. The preset box tilting device is controlled to tilt the empty box at a tilt angle value, while the packing robot is controlled to pack the product at the initial product placement position and collect placement image information. Based on the placement image information, determine whether the inner flap has returned to the preset qualified posture; If the inner flap has been returned to the correct position, the box tilting device will reset the empty box to a horizontal position to continue the subsequent packing operation. If the inner flap does not return to the correct position, pack the product using the preset tilting packing method.

8. The fully automatic packaging method for injection molding machines according to claim 7, characterized in that, The tilting packing method includes: When the inner flap does not return to the qualified posture, the product angle value is obtained based on the placement image information and preset product characteristics. The angle adjustment value is obtained based on the product angle value and the preset horizontal angle value; The secondary product placement position is generated based on the angle adjustment value, the box tilt angle value, and the initial product placement position. The control box tilting device dynamically corrects the box angle according to the angle adjustment value, so that the product is placed horizontally; Control the packing robot to pack products at the secondary product placement position and update the placement image information.

9. The fully automatic packaging method for injection molding machines according to claim 8, characterized in that, It also includes methods for adjusting the angle of the box when placing the product: When the packing robot is packing products, it captures real-time images of the product placement. The real-time angle value of the product is obtained based on the real-time placement image and product characteristics. The real-time angle adjustment value is obtained by combining the product's real-time angle value and horizontal angle value. The current angle value of the box is obtained based on the box tilt angle value and the angle adjustment value; The maximum real-time adjustment value is obtained by responding to the current angle value of the enclosure and the preset horizontal angle value of the enclosure; The control box tilting device adjusts the box angle according to the real-time angle adjustment value until the real-time angle adjustment value matches the maximum real-time adjustment value, at which point the angle adjustment stops.

10. A fully automatic packaging system for injection molding machines, characterized in that, include: The data acquisition module is used to collect equipment start-up signals, product packing information, and current label information; A memory for storing a program that implements a fully automatic packaging method for an injection molding machine as described in any one of claims 1 to 9; The processor is used to load and execute programs stored in memory.

Images