Full-automatic packaging system for injection molding workshop and working method

Abstract

The invention discloses a full-automatic packaging system for an injection molding workshop and a working method. The full-automatic packaging system comprises a main line, a production line, a boxing line and an empty box line. Wherein the main line is divided into a plurality of passing sections corresponding to the production line, each passing section operates independently, a plurality of groups of first sensors are arranged on the passing sections in the material flowing direction so as to sense the number and the position of materials entering the passing sections, and at least one group of first sensors is located behind a feeding point of the production line; the other first sensors are located in front of a feeding point of the production line, the passing section is suitable for stopping or operating according to the waiting time of feeding equipment, the number of entering materials and the position of the entering materials, and the passing section is provided with an interval stopper in front of the feeding point of the production line. The interval stopper is suitable for stopping or releasing the materials according to the waiting time of the feeding equipment and the number and position of the materials in the passing section, the conveying is smooth, the packaging efficiency is high, the blocking point of each link can be automatically relieved, and the production packaging efficiency is guaranteed.

Description

Technical Field

[0001] This application relates to the field of packaging equipment technology, specifically to a fully automated packaging system and its working method for an injection molding workshop. Background Technology

[0002] Automated packaging systems are continuous production lines that integrate mechanical, electronic, and computer control technologies to automatically transport, count, sort, package (such as bagging, boxing, labeling, sealing), and palletize products. Their core objective is to replace traditional manual packaging methods, improve production efficiency, reduce labor intensity and costs, and ensure the consistency and stability of packaging quality.

[0003] However, existing automated packaging systems have the following drawbacks: when materials are flowing through the main line, the system must wait for the next product to arrive at the designated detection area before the previous product can be released, resulting in low product outflow efficiency. Blockages are prone to occur during operation, and the system cannot automatically clear these blockages. In severe cases, the system needs to be shut down, affecting production efficiency. Summary of the Invention

[0004] One objective of this application is to provide a fully automated packaging system and operating method for injection molding workshops with high production and packaging efficiency.

[0005] To achieve the above objectives, the technical solution adopted in this application is: a fully automated packaging system for an injection molding workshop, comprising: Main line, suitable for material transfer; A production line includes production equipment and feeding equipment, wherein the production equipment is adapted to produce and process materials, and the feeding equipment is adapted to move the materials to the main line, and the feeding equipment is adapted to wait at the main line when moving the materials. A packing line includes packing equipment and outgoing equipment, wherein the packing equipment is adapted to sort and unload materials on the main line, and the outgoing equipment is adapted to pack the sorted materials into boxes. An empty box line includes conveying equipment and placement equipment, wherein the conveying equipment is adapted to replenish empty boxes to the packing line, and the placement equipment is adapted to grab empty boxes and place them at the outflow equipment; The main line is divided into multiple passage sections corresponding to the production line. Each passage section operates independently. Multiple sets of first sensors are arranged along the material flow direction on each passage section to sense the quantity and position of materials entering the passage section. At least one set of first sensors is located after the feeding point of the production line, and the remaining first sensors are located before the feeding point of the production line. The passage section is adapted to stop or start according to the waiting time of the feeding equipment, the quantity and position of the materials entering. An interval blocker is set in the passage section before the feeding point of the production line. The interval blocker is adapted to block or allow passage according to the waiting time of the feeding equipment, the quantity and position of the materials in the passage section.

[0006] In some embodiments, the spacing of the first sensors before the loading point of the production line is set according to the operating speed of the passage section, so as to form a collision zone and multiple warning zones in sequence from near to far before the loading point of the production line, and the warning range of the warning zones increases in sequence from near to far; the number of warning zones is three, namely a 1-second warning zone, a 2-second warning zone and a 3-second warning zone; the interval blocker is located in or before the collision zone, and the loading equipment, the passage section and the interval blocker are adapted to cooperate to allow the material in the collision zone to flow out preferentially; the loading equipment has a preset waiting time, and when the waiting time of the loading equipment exceeds the time limit, the passage section and the interval blocker are adapted to cooperate to restrict the flow of material in the warning zone, so as to allow the material on the loading equipment to be placed and flowed out preferentially.

[0007] In some embodiments, the feeding device is adapted to wait above the main line when moving materials, and the minimum distance between the materials on the feeding device and the main line is greater than the maximum height of the materials flowing on the main line; the feeding device includes a feeding robot, and the maximum duration of the feeding robot's lifting and lowering motion above the main line is greater than the minimum duration of the materials moving from the warning zone to the feeding point of the production line; the main line includes a plurality of spaced conveyor rollers, and the spacer is movably disposed in the gap between two adjacent conveyor rollers, and the spacer is adapted to rise above the upper surface of the main line to block materials, or to descend below the upper surface of the main line to allow materials to pass.

[0008] In some embodiments, a storage branch is provided on the packing line, the storage branch is connected to the main line and forms a buffer point at the main line, a pusher and a second sensor are provided at the buffer point, the second sensor is adapted to sense material, the pusher is adapted to push material to be temporarily stored by the signal of the first sensor and / or the second sensor, and the packing equipment is adapted to obtain the material temporarily stored in the storage branch; the number of storage branches is two, the two storage branches are arranged at intervals, and one or more spacers are provided between the two buffer points of the main line, the spacers are adapted to block or allow passage by the signal of the first sensor and / or the second sensor.

[0009] In some embodiments, the packing equipment includes a gantry robot, the outflow equipment includes multiple sets of conveyor lines, the gantry robot is arranged across the main line and the conveyor lines, the conveyor lines include an upper conveyor branch and a lower conveyor branch, the upper conveyor branch and the lower conveyor branch are layered vertically, and the two ends of the lower conveyor branch extend beyond the two ends of the lower conveyor branch, the gantry robot is adapted to place materials at one end of the upper conveyor branch or the lower conveyor branch, and the other end of the upper conveyor branch and the lower conveyor branch extends out of the packing area.

[0010] In some embodiments, the conveying device includes an empty box conveyor line, the placing device includes an empty box robot, the empty box conveyor line is adapted to be layered above and below the conveyor line, the empty box robot is disposed between adjacent conveyor lines, the empty box robot is adapted to grab empty boxes on the empty box conveyor line and place them on the conveyor line; the number of packing lines is two, and the empty box conveyor line is adapted to simultaneously connect to and replenish the two packing lines.

[0011] In some embodiments, the main line is provided with an RFID identification device between the production line and the packing line. The RFID identification device is adapted to identify the type of material and send the identification signal to the packing equipment, which is adapted to sort the material by the signal.

[0012] A method for operating a fully automated packaging system in an injection molding workshop, applicable to any of the aforementioned fully automated packaging systems in an injection molding workshop, includes the following steps: S100: The main line is configured with corresponding passage sections according to the number and location of the production lines. A first sensor is installed in each passage section to detect the quantity and location of the materials entering the passage section, and an interval barrier is installed. S200, adjust the waiting position of the loading robot to above the main line, and set the waiting time of the loading robot in each production line; S300: The production equipment in the production line completes the material production and processing, and the loading robot grabs the material and hovers above the main line to wait. S400: Based on the waiting time of the loading robot, the quantity of material in the passage section, and the position of the material in the passage section, the loading robot, the passage section, and the interval stop determine the material flow status and execute corresponding actions to ensure that the material passes through the current passage section in an orderly manner. The S500 packing line sorts and packs materials flowing on the main line, and the packing is automatically discharged after packing is completed.

[0013] S400 includes the following steps: S410: The loading robot has not been hovering for longer than the preset waiting time. No material has been detected in the collision zone or the warning zone. The loading robot places the material on the main line and executes the next cycle of material handling. S420 If the loading robot hovers for more than the preset waiting time and identifies materials in the collision zone, the materials in the collision zone will be released first. S430: If the loading robot hovers for longer than the preset waiting time, and one piece of material is detected in the warning zone, the barrier is raised to intercept it. The loading robot then places the material on the main line and executes the next cycle of material transport. If another piece of material is detected entering the warning zone during this process, and the number of materials in the warning zone becomes two, the first piece of material passes through the interval barrier, which is then opened. After the material flows out of the designated area, the interval barrier is lowered to allow the second piece of material to pass. When the number of materials in the warning zone reaches three, the operation of the current passage section is stopped, and the passage section resumes operation after the loading robot completes the material placement action. S440 If the loading robot hovers for longer than the preset waiting time, and two or more materials are detected in the warning zone, the operation of the current passage will be stopped, and the passage will resume operation after the loading robot places the materials.

[0014] S500 includes the following steps: S510 sets up a storage branch line on the main line. When the main line is congested, the storage branch line actively receives part of the material on the main line. When the packing equipment is idle, it grabs the material from the storage equipment and packs it into boxes. S520: The gantry robot in the packing line grabs the material on the main line and places it into the empty box on the upper or lower conveyor branch according to the material specifications. After the box is packed on the upper or lower conveyor branch, it automatically flows out to the rear for manual transfer. S530, the upper station of the empty box conveyor line affixes a code and label to the empty boxes, so that the empty boxes obtain a box number; S540: When the gantry robot grabs the last boxed material and completes the boxing, the empty box conveyor line and the empty box robot work together to automatically replenish the corresponding empty box to the replacement position.

[0015] Compared with the prior art, the beneficial effects of this application are as follows: 1. The fully automated packaging system for injection molding workshops in this application plans the sensing and detection area of ​​the main line, so that the products on the main line can be placed according to the sensing results to form sufficient feeding spacing. At the same time, the products in circulation can be blocked by the interval blockers for different times according to the sensing results, so as to achieve orderly circulation of the entire main line. It can adapt to the feeding and circulation needs of the main line of multiple production lines, and can actively clear the blockages in the process to ensure the efficiency of production and processing.

[0016] 2. The fully automated packaging system for the injection molding workshop of this application uses a gantry robot as a box-packing device, which can improve box-packing efficiency, pack incoming materials into boxes in real time, and free up space below to arrange outgoing equipment and empty box lines, etc., so that they can work together to achieve seamless box-packing outgoing and empty box replenishment. At the same time, with the help of the outgoing equipment, workers do not need to enter the box-packing area below the gantry robot to move the boxed goods. The gantry robot can perform box-packing operations without stopping the machine, thus improving production efficiency.

[0017] 3. The fully automated packaging system for the injection molding workshop in this application adds a storage branch line. When multiple production lines are operating simultaneously, if the transportation capacity of the boxing equipment reaches its limit, the main line may become congested. At this time, the storage branch line can be activated to actively store some products to alleviate the transportation pressure on the boxing equipment. Then, when the boxing equipment has excess transportation capacity, the products on the storage branch line can be boxed, thereby ensuring the smooth operation of the entire system.

[0018] 4. The empty carton line of the fully automated packaging system in the injection molding workshop of this application can replenish empty cartons to the packing line in a timely manner. One empty carton line can replenish empty cartons to multiple packing lines. At the same time, the replenishment operation of the empty carton line does not affect the packing operation of the packing line, so as to ensure the uninterrupted operation of the packing line and improve production efficiency. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of a production line according to a preferred embodiment of this application.

[0020] Figure 2 This is a schematic diagram of the main feed arrangement according to a preferred embodiment of this application.

[0021] Figure 3 This is a schematic diagram of the loading of a product line according to a preferred embodiment of this application.

[0022] Figure 4 This is a schematic plan view of the production line according to a preferred embodiment of this application.

[0023] Figure 5 This is a schematic diagram of the overall structure of the packing area according to a preferred embodiment of this application.

[0024] In the diagram: 1. Main line; 11. Passage section; 12. First sensor; 13. Loading point; 14. Interval barrier; 15. Collision zone; 16. 1-second warning zone; 17. 2-second warning zone; 18. 3-second warning zone; 19. Buffer point; 2. Production line; 21. Production equipment; 22. Loading robot; 3. Packing line; 31. Gantry robot; 32. Conveyor line; 321. Upper conveyor branch line; 322. Lower conveyor branch line; 4. Empty box line; 41. Empty box conveyor line; 42. Empty box robot; 5. Storage branch line; 6. Pusher; 7. Second sensor; 8. RFID identification device. Detailed Implementation

[0025] The present application will be further described below with reference to specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0026] In the description of this application, it should be noted that the directional terms such as "center", "lateral", "longitudinal", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", and "counterclockwise" indicate the orientation and positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. They should not be construed as limiting the specific protection scope of this application.

[0027] It should be noted that the terms "first," "second," etc., in the specification and claims of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence.

[0028] The terms “comprising” and “having”, and any variations thereof, in the specification and claims of this application are intended to cover non-exclusive inclusion, for example, a process, method, system, product, or device that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or device.

[0029] The following description, in conjunction with the accompanying drawings, further illustrates this application: like Figures 1 to 5 As shown, this application provides a fully automated packaging system for an injection molding workshop, comprising: Main line 1 is suitable for material transfer.

[0030] In some embodiments, the main line 1 is mainly composed of a conveyor belt or conveyor rollers, and the material falling onto the conveyor belt or conveyor rollers is suitable for moving and transferring along the main line 1.

[0031] Production line 2 includes production equipment 21 and feeding equipment. Production equipment 21 is suitable for producing and processing materials. Feeding equipment is suitable for moving materials to main line 1. When moving materials, feeding equipment is suitable for waiting at main line 1. Main line 1 can connect multiple production lines 2 to simultaneously process materials produced by multiple production lines 2 and perform sorting and packaging, thereby making full use of the packing capacity of packing line 3.

[0032] In some embodiments, the production equipment 21 includes plastic product manufacturing and processing equipment such as injection molding machines, and the feeding equipment includes transfer equipment such as a feeding robot 22. The feeding robot 22 is adapted to transfer the materials produced on the injection molding machine or other equipment to the main line 1.

[0033] Packing line 3 includes packing equipment and outgoing equipment. The packing equipment is suitable for sorting and unloading materials on the main line 1, and the outgoing equipment is suitable for packing the sorted materials into boxes.

[0034] In some embodiments, the packing equipment includes a gantry robot 31, and the outflow equipment includes multiple sets of conveyor lines 32. The gantry robot 31 is arranged across the main line 1 and the conveyor lines 32, which can free up the space below for arranging the main line 1, the conveyor lines 32 and the empty box line 4, reducing the space occupied by the packing equipment and reducing structural interference between different equipment. The gantry robot 31 is suitable for grabbing materials on the main line 1 and transferring them to the boxes on the corresponding conveyor lines 32.

[0035] In some embodiments, there are multiple gantry robots 31, and each gantry robot 31 corresponds to multiple sets of conveyor lines 32, which can improve packing efficiency and the utilization rate of the main line 1.

[0036] In some embodiments, the outflow device is mainly composed of a conveyor belt or conveyor rollers. The outflow device is suitable for transferring the boxed goods out from under the gantry robot 31, so that workers can receive and handle them. This eliminates the need for workers to enter the boxing area to handle the goods. The gantry robot 31 can keep the boxing action uninterrupted, ensuring production efficiency.

[0037] Empty box line 4 includes conveying equipment and placement equipment. The conveying equipment is adapted to replenish empty boxes to the packing line 3, and the placement equipment is adapted to grab empty boxes and place them at the outflow equipment.

[0038] In some embodiments, the conveying device is mainly composed of a conveyor belt or conveyor rollers, and the conveying device is adapted to transfer empty boxes to below the gantry robot 31 (on the outflow device). The placement device includes a placement robot adapted to grab empty boxes on the conveying device and place them below the gantry robot 31 (on the outflow device).

[0039] To ensure the smooth operation of the entire system, this application divides the layout of the main line 1 corresponding to the production line 2 into multiple passage sections 11. Each passage section 11 is connected to one production line 2, and each passage section 11 is suitable for independent operation. Multiple sets of first sensors 12 are arranged on the passage section 11 along the material flow direction to sense the quantity and position of the material entering the passage section 11. At least one set of first sensors 12 is located after the feeding point 13 of the production line 2, and the remaining first sensors 12 are located before the feeding point 13 of the production line 2. The passage section 11 is suitable for stopping or operating according to the waiting time of the feeding equipment, the quantity and position of the material entering, and the passage section 11 is equipped with an interval blocker 14 before the feeding point 13 of the production line 2. The interval blocker 14 is suitable for blocking or allowing passage according to the waiting time of the feeding equipment, the quantity and position of the material in the passage section 11.

[0040] It is understandable that by using the identification results of the first sensor 12 to make control logic judgments, and then by controlling the interval blocker 14 to block different materials for different durations, and combined with the stop or start control of the passage section 11, the conveying status and speed of different materials can be effectively changed to stagger the distance between adjacent materials, maintain the passage order of materials in the current passage section 11, avoid collisions and accumulation of materials in the passage section 11, and thus ensure the smooth operation of the entire system.

[0041] It is worth noting that the loading point 13 of production line 2 refers to the fixed point where the material on production line 2 is transferred to the main line 1 by the loading robot 22 and placed down. Under normal circumstances, the position of the loading point 13 in the flow direction of the main line 1 does not change, so as to ensure that the position of the loading point 13 can be matched with the data sensed by the first sensor 12 to accurately identify and judge the dynamics of the material.

[0042] In some embodiments, the first sensor 12 is a photoelectric sensor, which can remotely and accurately measure the position and quantity of materials on the main line 1, making the arrangement more flexible and convenient.

[0043] In some embodiments, the spacing of the first sensors 12 before the loading point 13 of the production line 2 is set according to the operating speed of the passage section 11, so as to form a collision zone 15 and multiple warning zones in sequence from near to far before the loading point 13 of the production line 2, and the warning range of the warning zone increases from near to far. Through the collision zone 15 and the warning zone, the dynamics of the material can be effectively identified and judged. As the material gets closer to the loading point 13 of the production line 2, the system's real-time dynamic sensing of the material can become more accurate, and then the interval blocker 14 and the passage section 11 can be controlled to change their state in a timely manner according to the sensing results.

[0044] like Figure 2In the embodiment shown, there are three warning zones: a 1-second warning zone 16, a 2-second warning zone 17, and a 3-second warning zone 18. When the material approaches the feeding point 13 of the production line 2, it will pass through the 3-second warning zone 18, the 2-second warning zone 17, and the 1-second warning zone 16 in sequence until it enters the collision zone 15.

[0045] Each collision zone 15 or warning zone is formed by at least two sets of first sensors 12. The outermost two first sensors 12 can serve as the boundaries of the collision zone 15 or warning zone. The more first sensors 12 inside each collision zone 15 or warning zone, the more accurate the sensing of the material's state.

[0046] It is worth noting that the partition barrier 14 is located within or before the collision zone 15. When the material enters the collision zone 15, it indicates that the material is about to pass through the feeding point 13 of the production line 2. At this time, if the feeding robot 22 is in the action state of transferring the material to the main line 1, the partition barrier 14 and the passage section 11 cannot restrict the passage of the material by changing their state. In this case, the two materials are likely to collide, affecting the smoothness of the material flow. Therefore, when the material enters the collision zone 15, the feeding equipment, the passage section 11 and the partition barrier 14 need to cooperate with each other to make the material in the collision zone 15 flow out first. The material outflow can be sensed by the first sensor 12 after the feeding point 13 of the production line 2.

[0047] Furthermore, to prevent the loading robot 22 from waiting above the main line 1 without finding an opportunity to place materials, thus affecting the next material transfer of the production line 2, this application presets a waiting time for the loading equipment. When the waiting time of the loading equipment exceeds the time limit, the unloading priority of the loading equipment is appropriately increased. The passage section 11 and the interval blocker 14 are adapted to cooperate to restrict the material flow within the warning zone, so that the materials on the loading equipment are placed and flowed out first, thereby ensuring that the materials on the production line 2 can be transferred and output in a timely manner, and avoiding affecting the production and processing of the production line 2.

[0048] like Figure 3 In the embodiment shown, when the feeding device moves the material, it is suitable to wait above the main line 1, and the minimum distance x between the material on the feeding device and the main line 1 is greater than the maximum height y of the material flowing on the main line 1. That is, the waiting state of the feeding device will not affect the material flow in the passage section 11. Considering the stability of machine operation and material placement, the feeding device can achieve the highest efficiency and the most stable placement by controlling the material to go straight up and down. Therefore, the feeding device is preferably waiting directly above the main line 1.

[0049] Furthermore, the maximum duration of the lifting and lowering motion of the loading robot 22 above the main line 1 is greater than the minimum duration of the material moving from the warning zone to the loading point 13 of the production line 2. This ensures that during the operation of the loading robot 22, the material flowing out of the warning zone will not collide with or come into contact with the placed material or the loading robot 22, thereby improving the stability and safety of the loading robot 22 during the placement process.

[0050] In some embodiments, the lifting action of the loading robot 22 is controlled to be completed within 2-3 seconds.

[0051] like Figure 2 In the illustrated embodiment, the main line 1 includes multiple spaced conveyor rollers. The advantage of the conveyor rollers is that they can be controlled individually or in clusters, providing greater control freedom and facilitating the adjustment and establishment of passage sections 11 of different lengths without requiring significant modifications to the main line 1. The spacer 14 is vertically and flexibly positioned in the gap between two adjacent conveyor rollers. The spacer 14 is suitable for rising above the upper surface of the main line 1 to block materials or descending below the upper surface of the main line 1 to allow materials to pass. The spacer 14 can fully utilize the gap between the conveyor rollers to achieve blocking and passage through lifting and lowering, resulting in higher space utilization. Furthermore, this type of spacer 14 does not cause compression or deformation of the materials when blocking, thereby ensuring the success rate of the subsequent gantry robot 31 grabbing materials for packing.

[0052] In some embodiments, the spacer 14 includes a partition and a driver (motor, cylinder, hydraulic cylinder, etc.), the driver being adapted to drive the partition to rise or fall.

[0053] In some embodiments, a storage branch line 5 is provided on the packing line 3. The storage branch line 5 is connected to the main line 1 and forms a buffer point 19 at the main line 1. A pusher 6 and a second sensor 7 are provided at the buffer point 19. The second sensor 7 is adapted to sense the material. The pusher 6 is adapted to push the material to be temporarily stored by the signal of the first sensor 12 and / or the second sensor 7. The packing equipment is adapted to obtain the material temporarily stored in the storage branch line 5.

[0054] In some embodiments, the gantry robot 31 is adapted to be positioned across the storage branch line 5 and is adapted to grab materials from the storage branch line 5 to the packing line 3 for packing.

[0055] In some embodiments, the second sensor 12 is a photoelectric sensor, which can remotely and accurately measure the position and quantity of materials on the main line 1, making its arrangement more flexible and convenient.

[0056] It is understandable that when the main line 1 connects to multiple production lines 2, the state of receiving and transferring materials on the main line 1 is not constant because the cycle time of each production line 2 may be different. The transfer efficiency will fluctuate over time. If the material transfer efficiency of the main line 1 exceeds the upper limit of the packing and conveying capacity of the gantry robot 31, the main line 1 is prone to material accumulation and congestion. At this time, the main line 1 can use the pusher 6 at the buffer point 19 to push some materials into the storage branch line 5 for storage to temporarily alleviate the congestion of the main line 1.

[0057] like Figure 4 In the illustrated embodiment, there are two storage branches 5, which are spaced apart. By staggering the two storage branches 5, the material flow distance between the two storage branches 5 is increased, thereby reducing the probability of congestion between the two buffer points 19 of the main line 1. One or more spacers 14 are provided between the two buffer points 19 of the main line 1. The spacers 14 are adapted to block or allow passage based on the signals of the first sensor 12 and / or the second sensor 7. By combining the signals of the first sensor 12 and the second sensor 7 with the spacers 14, the material on the main line 1 between the two storage branches 5 (between the two buffer points 19) can be sorted out, thus alleviating congestion.

[0058] In some embodiments, each set of storage branches 5 is designed to store 5 items, which are used for unblocking the main line 1 and buffering products, thereby alleviating the congestion problem of the main line 1 caused by the limited transport capacity of the gantry robot 31.

[0059] like Figure 5 In the illustrated embodiment, the conveyor line 32 includes an upper conveyor branch 321 and a lower conveyor branch 322, which are layered vertically. Both ends of the lower conveyor branch 322 extend beyond the upper conveyor branch 322. The gantry robot 31 is adapted to place materials at one end of either the upper conveyor branch 321 or the lower conveyor branch 322. The other ends of the upper conveyor branch 321 and the lower conveyor branch 322 extend into the packing area. The upper conveyor branch 321 and the lower conveyor branch 322 are staggered vertically, with the lower conveyor branch 322 located above the upper conveyor branch. The upper conveyor branch 321 is positioned directly below the lower conveyor branch 322, ensuring that it does not interfere with the loading of boxes by the gantry robot 31 at the lower conveyor branch 322, nor does it affect the workers' picking and handling of goods at the lower conveyor branch 322. When goods flow out of one of the upper and lower conveyor branches 321 and 322, the gantry robot 31 can load goods at the other conveyor branch, thereby improving loading efficiency, making full use of longitudinal space, adapting to the gripping operation of the gantry robot 31, and improving production efficiency while reducing space occupation.

[0060] In some embodiments, the upper conveyor branch line 321 and the lower conveyor branch line 322 are mainly composed of conveyor belts, which can more stably support and transport goods and reduce jamming. The upper conveyor branch line 321 and the lower conveyor branch line 322 are in a stopped state during the packing process. After the materials are packed, the upper conveyor branch line 321 and the lower conveyor branch line 322 automatically operate to discharge the goods outside the packing area, so that workers can easily handle the goods, and this process will not affect the gantry robot 31 from continuing to carry out the packing operation.

[0061] In some embodiments, the number of conveyor lines 32 is 5 sets, and the 5 sets of conveyor lines 32 are arranged in parallel. The gantry robot 31 spans the 5 sets of conveyor lines 32. The gantry robot 31 is adapted to grab materials on the main line 1 and place them in empty boxes on suitable conveyor lines 32.

[0062] like Figure 4 and 5 In the illustrated embodiment, the conveying equipment includes an empty box conveyor line 41, and the placement equipment includes an empty box robot 42. The empty box conveyor line 41 is adapted to be layered above and below the conveyor line 32, that is, the empty box conveyor line 41 is divided into an upper layer and a lower layer, which are respectively connected to the upper conveyor branch line 321 and the lower conveyor branch line 322. The empty box robot 42 is arranged between adjacent conveyor lines 32, utilizing the space between adjacent conveyor lines 32 to save space. The empty box robot 42 is suitable for grabbing empty boxes on the empty box conveyor line 41 and placing them on the conveyor line 32. The gantry robot 31 is suitable for packing materials into empty boxes on the stopped conveyor line 32.

[0063] like Figure 4 In the embodiment shown, there are two packing lines 3. The empty box conveyor line 41 is suitable for simultaneously connecting and supplying the two packing lines 3, which can reduce the space occupation and improve the overall compactness of the system.

[0064] In some embodiments, the empty carton conveyor line 41 can move the empty carton in different directions through the cooperation of structures such as robotic arms, rollers and pushers 6, so as to transfer it to the two packing lines 3.

[0065] In some embodiments, an labeling station is provided at the upper position of the empty box conveyor line 41. The labeling station is suitable for labeling empty boxes to facilitate subsequent empty box identification and feeding, as well as sorting, identification and packing by the gantry robot 31.

[0066] like Figure 4In the embodiment shown, an RFID identification device 8 is installed between the production line 2 and the packing line 3 on the main line 1. The RFID identification device 8 is suitable for identifying the type of material and sending the identification signal to the packing equipment. The packing equipment is suitable for sorting by the signal. The use of RFID in conjunction with electronic tags to identify products reduces product identification time and extends the main line 1. This can solve the problem that the long material scanning time in the prior art affects the operating efficiency of the main line 1.

[0067] In summary, the fully automated packaging system for injection molding workshops proposed in this application, through optimized layout, enables a continuous and orderly flow from material production and processing to boxing and operation. During the process, congestion and blockage are less likely to occur at each stage, and some stages are less likely to be underutilized and idle, effectively improving overall production efficiency, production stability, and production smoothness.

[0068] This application also provides a method for operating a fully automated packaging system in an injection molding workshop, applicable to any of the above embodiments of the fully automated packaging system in an injection molding workshop, including the following steps: S100, the main line 1 is configured with corresponding passage sections 11 according to the number and position of the production lines 2. The number of production lines 2 and the number of passage sections 11 are the same. Under normal circumstances, the length of each passage section 11 is configured to be the same. A first sensor 12 is set in each passage section 11 to detect the quantity and position of the material entering the passage section 11. The position in the passage section 11 is sensed and identified by arranging the first sensor 12 in the form of a collision zone 15 and a warning zone. An interval blocker 14 is set in or before the collision zone 15.

[0069] S200, adjust the waiting position of the loading robot 22 above the main line 1, set the waiting time of the loading robot 22 in each production line 2, and avoid the loading robot 22 waiting above the main line 1 for too long, which would affect the next feeding cycle of the production line 2.

[0070] S300, the production equipment 21 in production line 2 completes the material production and processing, the loading robot 22 grabs the material and hovers above the main line 1 to wait, the loading robot 22 can descend and release the material at any time according to the needs to improve the material release efficiency.

[0071] S400, based on the waiting time of the loading robot 22, the quantity of material in the passage section 11, and the position of the material in the passage section 11, the loading robot 22, the passage section 11, and the interval stopper 14 determine the material flow status and execute corresponding actions to ensure that the material passes through the current passage section 11 in an orderly manner.

[0072] S500, packing line 3 sorts and packs the materials flowing on main line 1. The sorting and grabbing process uses RFID identification equipment 8 to quickly identify the materials on main line 1. After packing is completed, the materials are automatically discharged.

[0073] S400 includes the following steps: S410, the loading robot 22 has not been hovering for longer than the preset waiting time. No material has been detected in the collision zone 15 and the warning zone. The loading robot 22 places the material on the main line 1 and executes the next cycle of material handling.

[0074] S420, if the hovering time of the loading robot 22 exceeds the preset waiting time, and a material is detected within the collision zone 15, the material within the collision zone 15 will be released first.

[0075] S430, if the hovering time of the loading robot 22 exceeds the preset waiting time, and one piece of material is detected in the warning zone, the barrier is raised to intercept it. The loading robot 22 places the material on the main line 1 and executes the next cycle of material transport. During this process, if another piece of material is detected entering the warning zone, and the number of materials in the warning zone becomes two pieces, the first piece of material passes through the interval barrier 14 and the interval barrier 14 is opened. After the material flows out of the designated area, the interval barrier 14 is lowered to allow the second piece of material to pass. When the number of materials in the warning zone reaches three pieces, the operation of the current passage section 11 is stopped, and the passage section 11 is resumed after the loading robot 22 completes the material placement action.

[0076] S440, if the hovering time of the loading robot 22 exceeds the preset waiting time, and materials are identified in the warning zone and the quantity is 2 or more, the operation of the current passage section 11 will be stopped, and the passage section 11 will resume operation after the loading robot 22 places the materials.

[0077] S500 includes the following steps: S510, a storage branch line 5 is set up on the main line 1. When the main line 1 is congested, the storage branch line 5 actively receives part of the material on the main line 1. When the packing equipment is idle, it grabs the material from the storage equipment and packs it into boxes.

[0078] S520, the gantry robot 31 in the packing line 3 grabs the material on the main line 1 and places it in the empty box of the upper conveyor branch 321 or the lower conveyor branch 322 of the conveyor line 32 according to the material specifications. After the box is packed on the upper conveyor branch 321 or the lower conveyor branch 322, it automatically flows out to the rear for manual transfer.

[0079] S530, the upper station of the empty box conveyor line 41 affixes a label to the empty boxes, so that the empty boxes obtain a box number.

[0080] S540, when the gantry robot 31 picks up the last boxed material and completes the boxing, the empty box conveyor line 41 and the empty box robot 42 work together to automatically replenish the corresponding empty box to the replacement position.

[0081] In some embodiments, the initial design operating time cycle of a single production line is 12s, which is equivalent to a line speed of 0.33m / s. This application arranges 9 production lines, all with an operating speed of 0.33m / s. When the material of the main line 1 enters the 3-second warning zone 18, the material of the main line 1 passes through first, and the material of the production line 2 must wait, but the waiting time shall not exceed the set waiting time (in this application, the waiting time is set by comprehensively considering the operating cycle and flow rate of the production line 2 and the flow rate of the main line 1, and is generally set to 30s). The gap blocker 14 between the collision zone 15 and the 1-second warning zone 16 forcibly stops the flow of the material of the main line 1 and allows the material of the production line 2 to pass.

[0082] Meanwhile, the following logic is set for the coordination between the loading robot 22 and the main line 1: a. When the loading robot 22 is in the set waiting time, if no material passes through the safe zone (the combination of part of the collision zone 15 and the warning zone can be set as the safe zone), the loading robot 22 will quickly put down the product and execute the next cycle of material handling.

[0083] b. If material enters the collision zone 15 after the set waiting time has elapsed by the loading robot 22, the material in the collision zone 15 must be released first, and then the following procedure must be executed: Program 1: When the system identifies that there is 1 piece of material in front of the loading point 13 of production line 2 and it has not reached the collision zone 15, the interval blocker 14 is activated to intercept the material behind. The loading robot 22 quickly places the material on the main line 1 and executes the next cycle of material transportation. During this process, if another piece of material is detected entering the interval and the number of materials in the area becomes 2 pieces, the interval blocker 14 is activated after the previous material reaches the blocking position. After the material flows out of the designated area, the blocker is deactivated to allow the material behind to pass. When the number of materials in the interval reaches 3 pieces, the operation of the current passage section 11 needs to be stopped, and the operation of the current passage section 11 is resumed after the loading robot 22 completes the material placement action.

[0084] Program 2: When the system identifies that there are 2 or more pieces of material in front of the loading point 13 of production line 2 and they have not reached the collision zone 15, the current passage section 11 is stopped and the current passage section 11 is resumed after the loading robot 22 is completed.

[0085] Using the above method to simulate the system, it can achieve stable operation for 12 hours, with no production line congestion and no loss of production capacity.

[0086] The basic principles, main features, and advantages of this application have been described above. Those skilled in the art should understand that this application is not limited to the above embodiments. The embodiments and descriptions in the specification are only the principles of this application. Various changes and modifications can be made to this application without departing from the spirit and scope of this application. All such changes and modifications fall within the scope of this application as claimed. The scope of protection claimed by this application is defined by the appended claims and their equivalents.

Claims

1. A fully automated packaging system for an injection molding workshop, characterized in that, include: Main line, suitable for material transfer; A production line includes production equipment and feeding equipment, wherein the production equipment is adapted to produce and process materials, and the feeding equipment is adapted to move the materials to the main line, and the feeding equipment is adapted to wait at the main line when moving the materials. A packing line includes packing equipment and outgoing equipment, wherein the packing equipment is adapted to sort and unload materials on the main line, and the outgoing equipment is adapted to pack the sorted materials into boxes. An empty box line includes conveying equipment and placement equipment, wherein the conveying equipment is adapted to replenish empty boxes to the packing line, and the placement equipment is adapted to grab empty boxes and place them at the outflow equipment; The main line is divided into multiple passage sections corresponding to the production line. Each passage section operates independently. Multiple sets of first sensors are arranged along the material flow direction on each passage section to sense the quantity and position of materials entering the passage section. At least one set of first sensors is located after the feeding point of the production line, and the remaining first sensors are located before the feeding point of the production line. The passage section is adapted to stop or start according to the waiting time of the feeding equipment, the quantity and position of the materials entering. An interval blocker is set in the passage section before the feeding point of the production line. The interval blocker is adapted to block or allow passage according to the waiting time of the feeding equipment, the quantity and position of the materials in the passage section.

2. The fully automated packaging system for an injection molding workshop as described in claim 1, characterized in that: The spacing of the first sensors before the feeding point of the production line is set according to the operating speed of the passage section, so as to form a collision zone and multiple warning zones in sequence from near to far before the feeding point of the production line, and the warning range of the warning zones increases from near to far; there are three warning zones, namely a 1-second warning zone, a 2-second warning zone and a 3-second warning zone; the interval blocker is located in or before the collision zone, and the feeding equipment, the passage section and the interval blocker are adapted to cooperate to allow the material in the collision zone to flow out first; the feeding equipment has a preset waiting time, and when the waiting time of the feeding equipment exceeds the time limit, the passage section and the interval blocker are adapted to cooperate to restrict the flow of material in the warning zone, so as to allow the material on the feeding equipment to be placed and flowed out first.

3. The fully automated packaging system for an injection molding workshop as described in claim 1, characterized in that: When the feeding device moves materials, it is adapted to wait above the main line, and the minimum distance between the materials on the feeding device and the main line is greater than the maximum height of the materials flowing on the main line; the feeding device includes a feeding robot, and the maximum duration of the feeding robot's lifting and lowering action above the main line is greater than the minimum duration of the materials moving from the warning zone to the feeding point of the production line; the main line includes a plurality of spaced conveyor rollers, and the spacer is movably arranged in the gap between two adjacent conveyor rollers, and the spacer is adapted to rise above the upper surface of the main line to block materials, or to descend below the upper surface of the main line to allow materials to pass.

4. The fully automated packaging system for an injection molding workshop as described in claim 1, characterized in that: The packing line is equipped with a storage branch line, which is connected to the main line and forms a buffer point at the main line. A pusher and a second sensor are installed at the buffer point. The second sensor is adapted to sense the material, and the pusher is adapted to push the material to be temporarily stored by the signal from the first sensor and / or the second sensor. The packing equipment is adapted to retrieve the material temporarily stored in the storage branch line. There are two storage branches, which are spaced apart. One or more spacers are installed between the two buffer points of the main line. The spacers are adapted to block or allow passage by the signal from the first sensor and / or the second sensor.

5. The fully automated packaging system for an injection molding workshop as described in claim 1, characterized in that: The packing equipment includes a gantry robot, and the outflow equipment includes multiple sets of conveyor lines. The gantry robot is arranged across the main line and the conveyor lines. The conveyor lines include an upper conveyor branch and a lower conveyor branch, which are layered vertically. The two ends of the lower conveyor branch extend beyond the two ends of the upper conveyor branch. The gantry robot is adapted to place materials at one end of the upper conveyor branch or the lower conveyor branch, and the other end of the upper conveyor branch and the lower conveyor branch extends out of the packing area.

6. The fully automated packaging system for an injection molding workshop as described in claim 5, characterized in that: The conveying equipment includes an empty box conveyor line, and the placement equipment includes an empty box robot. The empty box conveyor line is adapted to be layered on the conveyor line. The empty box robot is disposed between adjacent conveyor lines. The empty box robot is adapted to grab empty boxes on the empty box conveyor line and place them on the conveyor line. There are two packing lines. The empty box conveyor line is adapted to simultaneously connect and supply the two packing lines.

7. The fully automated packaging system for an injection molding workshop as described in claim 1, characterized in that: The main line is equipped with an RFID identification device between the production line and the packing line. The RFID identification device is suitable for identifying the type of material and sending the identification signal to the packing equipment. The packing equipment is suitable for sorting by the signal.

8. A method for operating a fully automated packaging system in an injection molding workshop, characterized in that, The fully automated packaging system for injection molding workshops, as described in any one of claims 1 to 7, comprises the following steps: S100: The main line is configured with corresponding passage sections according to the number and location of the production lines. A first sensor is installed in each passage section to detect the quantity and location of the materials entering the passage section, and an interval barrier is installed. S200, adjust the waiting position of the loading robot to above the main line, and set the waiting time of the loading robot in each production line; S300: The production equipment in the production line completes the material production and processing, and the loading robot grabs the material and hovers above the main line to wait. S400: Based on the waiting time of the loading robot, the quantity of material in the passage section, and the position of the material in the passage section, the loading robot, the passage section, and the interval stop determine the material flow status and execute corresponding actions to ensure that the material passes through the current passage section in an orderly manner. The S500 packing line sorts and packs materials flowing on the main line, and the packing is automatically discharged after packing is completed.

9. The working method of a fully automated packaging system in an injection molding workshop as described in claim 8, characterized in that, S400 includes the following steps: S410: The loading robot has not been hovering for longer than the preset waiting time. No material has been detected in the collision zone or the warning zone. The loading robot places the material on the main line and executes the next cycle of material handling. S420 If the loading robot hovers for more than the preset waiting time and identifies materials in the collision zone, the materials in the collision zone will be released first. S430: If the loading robot hovers for longer than the preset waiting time, and one piece of material is detected in the warning zone, the barrier is raised to intercept it. The loading robot then places the material on the main line and executes the next cycle of material transport. If another piece of material is detected entering the warning zone during this process, and the number of materials in the warning zone becomes two, the first piece of material passes through the interval barrier, which is then opened. After the material flows out of the designated area, the interval barrier is lowered to allow the second piece of material to pass. When the number of materials in the warning zone reaches three, the operation of the current passage section is stopped, and the passage section resumes operation after the loading robot completes the material placement action. S440 If the loading robot hovers for longer than the preset waiting time, and two or more materials are detected in the warning zone, the operation of the current passage will be stopped, and the passage will resume operation after the loading robot places the materials.

10. The working method of a fully automated packaging system in an injection molding workshop as described in claim 8, characterized in that, S500 includes the following steps: S510 sets up a storage branch line on the main line. When the main line is congested, the storage branch line actively receives part of the material on the main line. When the packing equipment is idle, it grabs the material from the storage equipment and packs it into boxes. S520: The gantry robot in the packing line grabs the material on the main line and places it into the empty box on the upper or lower conveyor branch according to the material specifications. After the box is packed on the upper or lower conveyor branch, it automatically flows out to the rear for manual transfer. S530, the upper station of the empty box conveyor line affixes a code and label to the empty boxes, so that the empty boxes obtain a box number; S540: When the gantry robot grabs the last boxed material and completes the boxing, the empty box conveyor line and the empty box robot work together to automatically replenish the corresponding empty box to the replacement position.

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