Automatic plate feeding and discharging control system and control method thereof

Abstract

The invention relates to the technical field of automatic control, in particular to an automatic plate feeding and discharging control system and a control method thereof. The method comprises the steps that transmission information is collected and sent to a central control system; a stacking occasion and a storage location are set, the cruising speed is obtained based on an optimization algorithm, and then plate movement is segmented to obtain the displacement distance of each segment; adjusting the maximum acceleration through the plate length, adjusting the maximum obstacle deceleration through the real-time obstacle distance, presetting an initial safety distance and speed response time, and determining a safety distance in combination with the speed at the current moment and the adjusted maximum obstacle deceleration; and plate control is completed based on the displacement distance of each stage and the safety distance monitored in real time. The problem of low efficiency is solved on the basis of solving the problem of energy waste.

Description

Technical Field

[0001] This application relates to the field of automation control technology, specifically to an automated loading and unloading control system and control method for sheet metal. Background Technology

[0002] In building construction, panels are a commonly used material, primarily for constructing ceilings, floors, and walls. They come in various types and sizes, and often require manual handling to move them to the construction site. Large panels, in particular, can be difficult to move. Traditional methods of transporting panels using manually operated overhead cranes are inefficient, require frequent positioning and calibration, and are prone to panel vibration, increasing the risk of falling and other safety hazards. Existing automated methods are unsuitable for longer panels and suffer from energy waste due to frequent speed variations during transport. Therefore, panel transportation suffers from both inefficiency and energy waste. Summary of the Invention

[0003] To address the technical problems of low efficiency and energy waste, this application provides an automated board loading and unloading control system and its control method. The specific technical solution adopted is as follows:

[0004] In a first aspect, this application proposes an automated material loading and unloading control method for sheet metal, which includes the following steps:

[0005] The data from the collected materials is transmitted to the central control system.

[0006] Set up material storage yards in the warehousing system and merge storage locations; divide the movement of the sheet metal into acceleration, constant speed and deceleration stages; obtain the cruising speed of the sheet metal during transportation through optimization algorithm, and determine the displacement distance of each stage by combining the maximum acceleration, total displacement distance, maximum deceleration and initial velocity of the sheet metal.

[0007] The system presets the optimal board length and adjusts the maximum acceleration based on the difference between the board length and the optimal board length; it also presets the maximum obstacle deceleration and adjusts the maximum obstacle deceleration based on the distance between the obstacle and the board and the maximum deceleration; and it presets the initial safe distance and speed response time, determining the safe distance by combining the current speed and the adjusted maximum obstacle deceleration.

[0008] The plate material is controlled based on the displacement distance at each stage and the real-time monitored safety distance.

[0009] In the above-mentioned scheme, this application first sets up a stockpile yard and merges storage locations, enabling the control system to control longer plates. Then, an optimization algorithm determines the displacement distance at each stage, saving energy during plate transportation. To address the vibration problem caused by excessively long plates, the acceleration is adaptively adjusted based on the plate length to prevent slippage. To address obstacles encountered during plate transportation, the transport speed is planned by real-time monitoring of obstacle distances, keeping the plate within a safe distance. Thus, the plate transportation path is planned and controlled, solving both energy waste and inefficiency issues.

[0010] In one embodiment, the transmitted information includes plate coordinates, roller coordinates, and the length and width of the plate.

[0011] In one embodiment, the material storage yard includes a loading storage yard and a unloading storage yard; the loading storage yard has 10 storage locations arranged in 2 rows and 5 columns; the unloading storage yard has 20 storage locations arranged in 2 rows and 10 columns; for long plates, the storage locations are merged and transported simultaneously, and the plates are placed from right to left.

[0012] In one embodiment, the method for obtaining the cruising speed of the sheet metal during transportation through an optimization algorithm, and determining the displacement distance at each stage by combining the maximum acceleration, total displacement distance, maximum deceleration, and initial velocity of the sheet metal, is as follows:

[0013] Construct a displacement distance function for each stage, and the sum of the three is the total displacement distance. Then, combine the cruising speed, maximum acceleration, and maximum deceleration to construct the relationship between the initial and final times of each stage. Solve to obtain the initial and final times of each stage, thereby determining the time interval of each stage, and obtain the displacement distance of each stage based on the time interval.

[0014] In one embodiment, the displacement distance function is:

[0015] s2(t)=v c ×(t2―t1), a max Let v represent the maximum acceleration, t1 represent the first moment, t2 represent the second moment, t3 represent the third moment, and v represent the maximum acceleration. c Indicates cruising speed, a dcc s1(t) represents the maximum deceleration, s2(t) represents the displacement during the acceleration phase, s3(t) represents the displacement during the constant velocity phase, and v0 represents the initial velocity of the plate.

[0016] In one embodiment, the method for obtaining the initial and ending times of each stage is as follows:

[0017] v c Indicates cruising speed, a max a represents the maximum acceleration. dcc The maximum deceleration is represented by t1, t2, and t3. The first time is the end of the acceleration phase and the beginning of the constant velocity phase, the second time is the end of the constant velocity phase and the beginning of the deceleration phase, and the third time is the end of the deceleration phase.

[0018] In one embodiment, the method for adjusting the maximum acceleration based on the difference between the plate length and the preferred plate length is as follows:

[0019] L0 is the preferred plate length, L is the plate length, exp() represents an exponential function with the natural constant as the base, min() represents a minimum function, and a max a represents the maximum acceleration. m This indicates the adjusted maximum acceleration.

[0020] In one embodiment, the method for adjusting the maximum obstacle deceleration based on the distance between the obstacle and the plate, and the maximum deceleration, is as follows:

[0021] a dd =(a d ,a dcc +0.1×(Δd) ―0.5 ), a d a represents the maximum obstacle deceleration. dcc The maximum deceleration is represented by Δd, and the real-time distance to the obstacle is represented by a. dd This indicates the adjusted maximum obstacle deceleration;

[0022] The maximum obstacle deceleration is the distance between the obstacle and the board.

[0023] In one embodiment, the expression for the safety distance is:

[0024] d s t represents the initial safe distance. s Let v(t) represent the velocity response time, v(t) represent the velocity at the current moment, and a represent the velocity response time. dd d represents the adjusted maximum obstacle deceleration. safe (t) represents the safe distance.

[0025] On the other hand, this application also provides an automated board loading and unloading control system, including a memory, a processor, and a computer program stored in the memory and running on the processor. When the processor executes the computer program, it implements the steps of any of the above-described automated board loading and unloading control methods.

[0026] The beneficial effects of this application are as follows:

[0027] This application first establishes a stockpile yard and merges storage locations, enabling the control system to manage longer plates. Then, an optimization algorithm determines the displacement distance at each stage, saving energy during plate transportation. To address the vibration problem caused by excessively long plates, acceleration is adaptively adjusted based on plate length to prevent slippage. To address obstacles encountered during transport, the transport speed is planned by real-time monitoring of obstacle distances, ensuring the plates remain within a safe distance. This path planning and control of plate transportation solves both energy waste and inefficiency issues. Attached Figure Description

[0028] To more clearly illustrate the technical solutions and advantages in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0029] Figure 1 This is a flowchart of an automated board loading and unloading control method provided in one embodiment of this application. Detailed Implementation

[0030] To further illustrate the technical means and effects adopted by this application to achieve the intended purpose of the invention, the following, in conjunction with the accompanying drawings and preferred embodiments, details the specific implementation, structure, features, and effects of an automated loading and unloading control system and its control method for sheet metal according to this application. In the following description, different "one embodiment" or "another embodiment" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form.

[0031] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0032] An embodiment of an automated board loading and unloading control system and its control method:

[0033] The following description, in conjunction with the accompanying drawings, details the specific scheme of the automated loading and unloading control system and control method for sheet metal provided in this application.

[0034] Please see Figure 1 The diagram illustrates a flowchart of an automated board loading and unloading control method according to an embodiment of this application. The method includes the following steps:

[0035] Step S001: Collect and transmit information to the central control system.

[0036] The WMS (Warehouse Management System) receives task instructions input manually on the host computer or reserved by MES (Manufacturing Execution System), and dispatches the tasks to the WCS (Warehouse Control System). The WCS decomposes the task instructions and sends them to the automated central control system. The automated central control system schedules the gantry crane and vacuum suction cup lifting device, and with the cooperation of the loading and unloading roller conveyor control system, realizes intelligent transfer and storage of the boards.

[0037] Transmitted information via WMS, including plate coordinates, roller coordinates, and the length and width of the plate.

[0038] At this point, the transmission information is sent via WMS.

[0039] Step S002: Set up the stacking location and storage location, obtain the cruising speed based on the optimization algorithm, and then divide the plate movement into segments to obtain the displacement distance of each segment.

[0040] To improve the efficiency of sheet material transportation and accelerate sheet material turnover, the plan layout of sheet material storage and logistics scheduling in the loading and unloading yards is designed. The loading yard has 10 storage locations arranged in 2 rows and 5 columns; the unloading yard has 20 storage locations arranged in 2 rows and 10 columns; and several locations in the unloading yard are designated as locations for non-conforming products.

[0041] For longer sheets, storage locations are combined for simultaneous transport, with sheets placed from right to left, adding as many sheets as possible to prevent mechanical interference. The transmission information is then sent to the WCS (Wastewater Control System) to control the sheet transport. In this embodiment, the storage location is 5000mm in size, the sheet length is 12000mm, and three storage locations are required.

[0042] During transportation, different speed models are used for different road sections, dividing the sheet motion into three stages: acceleration, constant speed, and deceleration. By switching between different speed stages, the sheets can be delivered to their destination more quickly and energy-efficiently using a gantry crane and vacuum suction cups with the aid of loading and unloading roller conveyors.

[0043] To save energy, an optimization algorithm is used to iterate at different speeds, and the speed that consumes the least energy is obtained through experiments as the cruising speed, which is the speed of the constant speed segment.

[0044] Even though this application uses multiple storage locations to combine and place the boards, the boards will still sway during transportation. To prevent swaying, a maximum acceleration needs to be set. In this embodiment, the maximum acceleration is 0.3. In addition, during the deceleration section, based on the braking performance of the roller conveyor, to prevent damage to the roller conveyor, the maximum deceleration needs to be limited. In this embodiment, it is set to 0.35.

[0045] Therefore, based on cruising speed, maximum acceleration, maximum deceleration, and total displacement, a function is constructed to obtain the time and position intervals for each stage. The total displacement is the distance between the starting and destination positions of the plate.

[0046] The displacement expressions for the three stages are:

[0047] s2(t)=v c ×(t2―t1), a max Let v represent the maximum acceleration, t1 represent the first moment, t2 represent the second moment, t3 represent the third moment, and v represent the maximum acceleration. c Indicates cruising speed, a dcc s1(t) represents the maximum deceleration, s2(t) represents the displacement during the acceleration phase, s3(t) represents the displacement during the constant velocity phase, and v0 represents the initial velocity of the plate. The initial velocity of the plate is 0 when it just begins to move.

[0048] The three moments and their relationship are determined based on cruising speed, maximum acceleration, and minimum acceleration.

[0049] v c Indicates cruising speed, a max a represents the maximum acceleration. dcc Let t1 represent the maximum deceleration, t2 represent the first moment, t3 represent the second moment, and t3 represent the third moment. The first moment is the end of the acceleration phase and the beginning of the constant velocity phase, the second moment is the end of the constant velocity phase and the beginning of the deceleration phase, and the third moment is the end of the deceleration phase.

[0050] Since the total displacement of the three stages is known, we can obtain the first, second, and third time points by combining all the equations and solving them.

[0051] This allows us to obtain the time intervals and displacement of the sheet material during the acceleration, constant speed, and deceleration phases during transportation.

[0052] At this point, the displacement distance for each stage has been obtained.

[0053] Step S003: Adjust the maximum acceleration by the length of the board, adjust the maximum obstacle deceleration by the real-time obstacle distance, and determine the safe distance by combining the speed and distance.

[0054] During transportation, simultaneous transport of boards may cause collisions, and when the boards are too long, they may still shake, affecting the transport process.

[0055] When the board is too long, using the maximum acceleration will cause the board to shake, reduce the suction cup's adhesion, and potentially cause danger. Therefore, the maximum acceleration needs to be adjusted based on the board length.

[0056] The longer the board length, the more severe the vibration, and the lower the acceleration required.

[0057] In this application, a preferred plate length is given. When the plate is of the preferred plate length, the acceleration is the maximum acceleration. The longer the plate, the smaller the acceleration, and the shorter the plate, the greater the acceleration.

[0058] The maximum acceleration function is constructed based on the acceleration mapping of the plate length.

[0059] L0 is the preferred plate length, L is the plate length, exp() represents an exponential function with the natural constant as the base, min() represents a minimum function, and a max a represents the maximum acceleration. m This indicates the adjusted maximum acceleration.

[0060] For obstacles that may appear during the transportation of the boards, real-time monitoring is required, and the boards should be slowed down in an emergency to avoid the obstacles.

[0061] When the plate material is used for obstacle avoidance, its maximum deceleration 'a' needs to be limited. dcc To prevent excessive deceleration from causing plate slippage, the maximum deceleration is determined by the plate's own coefficient of friction, and is referred to as the maximum obstacle avoidance deceleration. In this embodiment, the maximum obstacle avoidance deceleration is 0.5.

[0062] The distances between obstacles and materials are obtained through LiDAR point cloud processing and recorded as the real-time obstacle distance. The maximum obstacle avoidance deceleration is determined based on the real-time obstacle distance; the larger the real-time obstacle distance, the smaller the maximum obstacle avoidance deceleration, and vice versa.

[0063] The expression for the maximum obstacle deceleration is:

[0064] a dd =(a d ,a dcc +0.1×(Δd) ―0.5 ), a d a represents the maximum obstacle deceleration. dcc The maximum deceleration is represented by Δd, and the real-time distance to the obstacle is represented by a. dd This represents the adjusted maximum obstacle deceleration.

[0065] To prevent collisions with obstacles while maintaining a stable transport speed, a safety distance needs to be set. This safety distance is determined based on the current speed and the maximum obstacle deceleration. Since system control requires time, the system's speed response time must be considered when calculating the safety distance; this time is obtained through system testing. To ensure a certain level of safety, an initial safety distance is set; in this embodiment, the initial safety distance is 0.5, and the system's speed response time is 0.8.

[0066] d s t represents the initial safe distance. s Let v(t) represent the velocity response time, v(t) represent the velocity at the current moment, and a represent the velocity response time. dd d represents the adjusted maximum obstacle deceleration. safe (t) represents the safe distance.

[0067] Thus, the maximum acceleration and safe distance during the transportation of the sheet metal were obtained.

[0068] Step S004: Complete the plate control based on the displacement distance of each stage and the real-time monitored safety distance.

[0069] Through the above steps, after the transmission information is sent to the central control system, before the sheet material is transported, the maximum acceleration of the sheet material is first determined based on its length, and then a function is constructed based on the cruising speed, maximum acceleration, maximum deceleration and total displacement to obtain the transport plan of the sheet material.

[0070] Subsequently, during the transportation of the sheet metal, obstacles are monitored in real time. When an obstacle is encountered, the distance between the sheet metal and the obstacle is transmitted to the central control system to analyze the deceleration and determine a safe distance to continue the transportation of the sheet metal.

[0071] Based on the above steps, the control of board loading and unloading is completed.

[0072] Based on the same inventive concept as the above method, this embodiment of the invention also provides an automated board loading and unloading control system, including a memory, a processor, and a computer program stored in the memory and running on the processor. When the processor executes the computer program, it implements the steps of any one of the above-described automated board loading and unloading control methods.

[0073] It should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

[0074] The various embodiments in this specification are described in a progressive manner. The same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on describing the differences from other embodiments.

Claims

1. A method for automated loading and unloading control of sheet metal, characterized in that, The method includes the following steps: The data from the collected materials is transmitted to the central control system. Set up material storage yards in the warehousing system and merge storage locations; divide the movement of the sheet metal into acceleration, constant speed and deceleration stages; obtain the cruising speed of the sheet metal during transportation through optimization algorithm, and determine the displacement distance of each stage by combining the maximum acceleration, total displacement distance, maximum deceleration and initial velocity of the sheet metal. The system presets the optimal board length and adjusts the maximum acceleration based on the difference between the board length and the optimal board length; it also presets the maximum obstacle deceleration and adjusts the maximum obstacle deceleration based on the distance between the obstacle and the board and the maximum deceleration; and it presets the initial safe distance and speed response time, determining the safe distance by combining the current speed and the adjusted maximum obstacle deceleration. The plate material is controlled based on the displacement distance at each stage and the real-time monitored safety distance.

2. The automated loading and unloading control method for sheet metal as described in claim 1, characterized in that, The transmitted information includes the plate coordinates, roller coordinates, and the length and width of the plate.

3. The automated loading and unloading control method for sheet metal as described in claim 1, characterized in that, The material storage yard includes a loading storage yard and a unloading storage yard; the loading storage yard has 10 storage locations arranged in 2 rows and 5 columns; the unloading storage yard has 20 storage locations arranged in 2 rows and 10 columns; for long plates, the storage locations are combined and transported simultaneously, and the plates are placed from right to left.

4. The automated loading and unloading control method for sheet metal as described in claim 1, characterized in that, The method for obtaining the cruising speed of the sheet metal during transportation through an optimization algorithm, and determining the displacement distance at each stage by combining the maximum acceleration, total displacement distance, maximum deceleration, and initial velocity of the sheet metal, is as follows: Construct a displacement distance function for each stage, and the sum of the three is the total displacement distance. Then, combine the cruising speed, maximum acceleration, and maximum deceleration to construct the relationship between the initial and final times of each stage. Solve to obtain the initial and final times of each stage, thereby determining the time interval of each stage, and obtain the displacement distance of each stage based on the time interval.

5. The automated loading and unloading control method for sheet metal as described in claim 4, characterized in that, The displacement distance function is: s2(t)=v c ×(t2―t1), a max Let v represent the maximum acceleration, t1 represent the first moment, t2 represent the second moment, t3 represent the third moment, and v represent the maximum acceleration. c Indicates cruising speed, a dcc s1(t) represents the maximum deceleration, s2(t) represents the displacement during the acceleration phase, s3(t) represents the displacement during the constant velocity phase, and v0 represents the initial velocity of the plate.

6. The automated loading and unloading control method for sheet metal as described in claim 4, characterized in that, The method for obtaining the initial and ending times of each stage is as follows: v c Indicates cruising speed, a max a represents the maximum acceleration. dcc The maximum deceleration is represented by t1, t2, and t3. The first time is the end of the acceleration phase and the beginning of the constant velocity phase, the second time is the end of the constant velocity phase and the beginning of the deceleration phase, and the third time is the end of the deceleration phase.

7. The automated loading and unloading control method for sheet metal as described in claim 1, characterized in that, The method for adjusting the maximum acceleration based on the difference between the plate length and the preferred plate length is as follows: L0 is the preferred plate length, L is the plate length, exp() represents an exponential function with the natural constant as the base, min() represents a minimum function, and a max a represents the maximum acceleration. m This indicates the adjusted maximum acceleration.

8. The automated loading and unloading control method for sheet metal as described in claim 1, characterized in that, The method for adjusting the maximum obstacle deceleration based on the distance between the obstacle and the plate, as well as the maximum deceleration, is as follows: a dd =(a d ,a dcc +0.1×(Δd) ―0.5 ), a d a represents the maximum obstacle deceleration. dcc The maximum deceleration is represented by Δd, and the real-time distance to the obstacle is represented by a. dd This indicates the adjusted maximum obstacle deceleration; The maximum obstacle deceleration is the distance between the obstacle and the board.

9. The automated loading and unloading control method for sheet metal as described in claim 1, characterized in that, The expression for the safety distance is: d s t represents the initial safe distance. s Let v(t) represent the velocity response time, v(t) represent the velocity at the current moment, and a represent the velocity response time. dd d represents the adjusted maximum obstacle deceleration. safe (t) represents the safe distance.

10. An automated loading and unloading control system for sheet metal, comprising a memory, a processor, and a computer program stored in the memory and running on the processor, characterized in that, When the processor executes the computer program, it implements the steps of the automated loading and unloading control method for sheet metal as described in any one of claims 1-9.

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