A vertical set egg counting device and counting method based on multiple sensors

Abstract

The application discloses a vertical egg collecting counting device and counting method based on multiple sensors, relates to the field of livestock breeding counting, and comprises a fixing frame, sensor assemblies installed side by side on the fixing frame and a controller connected with the sensor assemblies, wherein the fixing frame is fixed on a vertical egg collecting elevator and located above an egg dropping port of the vertical egg collecting elevator, and the fixing frame spans the vertical egg collecting elevator; the sensor assembly comprises a sensor support fixed on the fixing frame and a sensor installed on the sensor support; a group of sensor assemblies are arranged correspondingly to each egg claw gap, and the sensor irradiates the egg claw gap of the vertical egg collecting elevator; the sensor is connected with the controller; and the controller is connected with a counter, a timer and an alarm. The fixing frame spans the vertical egg collecting elevator and is installed above the egg dropping port, thereby providing stable support for the sensor assemblies, adapting to the vertical egg collecting mode and widening the application range of the counting device.

Description

Technical Field

[0001] This invention relates to the field of livestock farming counting, and in particular to a vertical egg collection and counting device and method based on multiple sensors. Background Technology

[0002] In egg-laying hen farms, vertical egg-collecting elevators are crucial equipment for transporting eggs from the henhouse to the collection platform. Currently, most farms still use manual counting or horizontal egg-collecting belt counting devices. However, these methods have the following problems in vertical egg-collecting scenarios: 1. Incompatibility with vertical egg-collecting structures: Horizontal egg-collecting belt counting devices are usually installed above the belt, while vertical egg-collecting elevators use a multi-layered egg claw structure. Eggs are vertically distributed during the lifting process, and traditional counting devices cannot effectively detect eggs in the gaps between the claws, leading to inaccurate counting or omissions. 2. Complex sensor installation and difficult debugging: Since the spacing between the egg claws in a vertical egg-collecting elevator may vary depending on the equipment model, the sensors of existing counting devices are difficult to adjust after being fixed, requiring repeated calibration during installation, resulting in high maintenance and replacement costs. 3. Insufficient counting reliability: Some existing counting devices use mechanical contact counting (such as lever triggering), which may scratch the egg surface and affect egg quality; while photoelectric sensors, if improperly installed, are easily interfered with by the movement of the egg claws, resulting in false triggers or missed detections. Summary of the Invention

[0003] The purpose of this invention is to provide a vertical egg collection and counting device and method based on multiple sensors, which changes the current situation where the counting device is installed above the horizontal egg collection belt, and shifts the counting position to the vertical egg collection position to meet the counting requirements of different egg collection methods.

[0004] To achieve the above objectives, the present invention provides a vertical egg collecting and counting device based on multiple sensors, including a fixed frame, sensor assemblies mounted side-by-side on the fixed frame, and a controller that is signal-connected to the sensor assemblies; the fixed frame is fixed to a vertical egg collecting elevator, located above the egg drop opening of the vertical egg collecting elevator, and spans across the vertical egg collecting elevator; the sensor assembly includes a sensor bracket fixed to the fixed frame and sensors mounted on the sensor bracket; a set of sensor assemblies is provided for each egg claw gap, and the sensors illuminate the egg claw gaps of the vertical egg collecting elevator; the sensor signals are connected to the controller, which is located on one side of the vertical egg collecting elevator.

[0005] With the above structure, a fixed frame spans the vertical egg-collecting elevator and is installed above the egg-dropping opening, adapting to the vertical egg-collecting breeding model. This ensures the counting device is accurately positioned, broadening its application range and guaranteeing effective detection of eggs during vertical egg collection. A set of sensor components is installed for each egg claw gap. The sensors illuminate the gaps in the vertical egg-collecting elevator's egg claws, enabling precise detection of the eggs in each gap, achieving targeted detection, improving accuracy, and avoiding missed or false detections. The sensor signals are connected to a controller, which is located on one side of the vertical egg-collecting elevator. This facilitates signal transmission, ensuring that signals detected by the sensors are promptly transmitted to the controller for processing. Furthermore, the controller's location is optimized for convenient operation and maintenance.

[0006] Preferably, a nozzle is also fixed on the sensor bracket. The nozzle is connected to an air supply device, and the air jet direction of the nozzle is upward, located at the front end of the sensor's transmitting end. By blowing air into the sensor's transmitting end through the nozzle, an airflow isolation is formed, effectively reducing the probability of dust or feathers passing through or falling onto the sensor from the front end and causing prolonged obstruction, reducing the possibility of the sensor being falsely triggered, and improving the reliability of detection.

[0007] A counting method for a vertical egg-collecting counting device based on any of the above-mentioned multiple sensors includes the following steps:

[0008] S1. Detect the position of the egg using a sensor array;

[0009] S2. When any sensor is triggered, the collision zone and a timer are started simultaneously, and all the egg claw gaps corresponding to the triggered sensors are identified as suspected eggs within the collision zone.

[0010] S3. Verify the trigger duration of the sensor triggered at each suspected egg location: if the sensor trigger duration exceeds the preset timing length, it is determined to be a valid egg, and the egg count is incremented by 1; if the sensor trigger duration does not exceed the timing length, it is determined to be an invalid trigger.

[0011] S4. When the timer expires, the program stops, waits for the next row of eggs to arrive, and then continues with step S1.

[0012] The sensor array comprehensively covers the detection area, accurately acquiring egg location information and providing a foundation for accurate subsequent counting. When any sensor is triggered, a collision zone and a timer cycle are simultaneously activated. Within the collision zone, all locations corresponding to the triggered sensors in the egg claw gaps are identified as potential eggs. The collision zone and timer cycle help distinguish the detection of eggs from different rows, avoiding confusion. Identifying the locations of the sensors triggered within the collision zone as potential eggs allows for preliminary screening of areas where eggs may be present, improving counting efficiency. Determining whether a sensor is a valid egg by checking if its trigger duration exceeds a preset timer effectively avoids erroneous counting due to brief interference or false triggers, improving counting accuracy. This cyclical detection method can continuously count eggs during the vertical egg collection process, meeting the needs of continuous production.

[0013] Preferably, S3 also includes the following condition: when each sensor has a trigger time upper limit, the sensor will forcibly stop triggering when the trigger time upper limit is reached, and the egg count will increment by 1; wherein the trigger time upper limit satisfies: timing length ≤ trigger time upper limit ≤ one round time - the line-hitting interval. For special egg conditions such as upright placement that may cause the sensor to trigger for a long time, setting a trigger time upper limit can avoid affecting the counting of the next layer of eggshells, ensuring the accuracy and continuity of the counting. This condition ensures the rationality of the trigger time upper limit setting, preventing valid eggs from not being counted due to an excessively short trigger time upper limit, and preventing the trigger time upper limit from affecting the next round of counting due to an excessively long trigger time upper limit.

[0014] Preferably, S4 also includes the condition that the program stops when all sensors stop triggering. Stopping the program when all sensors stop triggering avoids unnecessary program execution, saves system resources, and ensures that the program does not malfunction when there are no eggs detected.

[0015] Preferably, a logical framework for a counting process is constructed, including the following processes:

[0016] T1, Start;

[0017] T2. When any sensor is triggered, start the timer for the crossing section and start a round of timer; record the crossing time of each egg;

[0018] T3. Determine if the time of the collision is within the collision interval; if it is within the collision interval, proceed to the next step; if it is not within the collision interval, no further determination is made.

[0019] T4. For each sensor triggered within the collision zone, determine whether the trigger time limit has been reached. If the trigger time limit has been reached, the sensor is set. If the trigger time limit has not been reached, determine whether the sensor should stop triggering. If the sensor stops triggering, the sensor is set. If the sensor does not stop triggering, continue to determine whether the trigger time limit has been reached until all sensors are set.

[0020] T5. Record the sensor setting time and determine whether the sensor trigger duration meets the timing length. If the sensor trigger duration meets the timing length, increment the number of eggs by 1; otherwise, it is an invalid time and is not counted during invalid time.

[0021] T6. After the timing in S2 starts, determine whether a round of time has been reached. If it has, end this process; if not, determine whether all sensor triggers have ended; if the sensor triggers have ended, also end this process; if the sensor triggers have not ended, continue determining whether a round of time has been reached until the process ends.

[0022] After adopting the above counting scheme, the beneficial effects of the present invention are:

[0023] This invention provides a vertical egg collecting and counting device and method based on multiple sensors. This invention solves the problem that existing counting devices are installed above the horizontal egg collecting belt and cannot be adapted to the counting of vertical egg collecting elevators. This invention uses a fixed frame to transfer the counting position to the vertical egg collecting position to meet the counting requirements of different egg collecting methods. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the installation position of a vertical egg counting device with multiple sensors according to the present invention;

[0025] Figure 2 yes Figure 1 A magnified view of part A in the image;

[0026] Figure 3 This is a schematic diagram of the structure of a vertical egg counting device with multiple sensors according to the present invention;

[0027] Figure 4 This is a schematic diagram of the nozzle installation position in Example 3;

[0028] Figure 5 This is a schematic diagram of the process of this device;

[0029] Figure 6 This is a schematic diagram of the control logic of this device.

[0030] In the diagram, 1 is the mounting bracket, 2 is the sensor assembly, 21 is the sensor bracket, 22 is the sensor, 23 is the nozzle, 5 is the vertical egg collection elevator, 51 is the egg drop opening, and 52 is the egg claw. Detailed Implementation

[0031] The invention will now be further described with reference to the accompanying drawings.

[0032] The orientations mentioned in this specification are based on the orientation of the vertical egg collecting and counting device and counting method based on multiple sensors of the present invention when it is working normally. They do not limit the orientation during storage and transportation, but only represent relative positional relationships, not absolute positional relationships.

[0033] Example 1:

[0034] like Figure 1 , Figure 2 and Figure 3 As shown, a vertical egg counting device based on multiple sensors includes a fixed frame 1, sensor assemblies 2 mounted side by side on the fixed frame 1, and a controller that is connected to the sensor assemblies 2.

[0035] The mounting bracket 1 is fixed to the vertical egg-collecting elevator 5, positioned above the egg-drop inlet 51 of the elevator 5, and spans across the elevator 5. In this embodiment, the mounting bracket 1 is fixedly installed on both sides of the vertical egg-collecting elevator 5, providing a stable mounting base for the sensor assembly 2. The mounting bracket 1, positioned above the egg-drop inlet 51 of the vertical egg-collecting elevator 5, adapts to the vertical egg-collecting breeding model, broadening the application range of the counting device. The sensor assembly 2 is mounted side-by-side on the mounting bracket 1, facilitating centralized debugging during commissioning, improving debugging efficiency, and reducing debugging time and workload.

[0036] The sensor assembly 2 includes a sensor bracket 21 fixed on the mounting frame 1 and a sensor 22 mounted on the sensor bracket 21. In this embodiment, the sensor 22 is a diffuse reflection photoelectric sensor. The sensor 22 illuminates the gaps in the egg claws 52 of the vertical egg collecting elevator 5. A set of sensor assemblies 2 is set for each gap in the egg claws 52. The sensor 22 is connected to a controller, which is located on one side of the vertical egg collecting elevator 5 (not shown in the figure). The sensor assembly 2 has a response time of less than 10ms and can transmit signals to the controller at high speed. This non-contact detection method will not cause the eggs to break, thus ensuring the quality of the eggs.

[0037] When eggs are transported on the vertical egg collection elevator 5, they are supported between two egg claws 52. When the diffuse reflection photoelectric sensor emits infrared or visible light to illuminate the gap between the egg claws 52, as the egg gradually descends, it enters the detection area, and the light is reflected back to the receiver, triggering a signal (response time <10ms).

[0038] like Figure 5 As shown, the egg claws 52 of the vertical egg-collecting elevator 5 move downwards (in the direction of the arrow), and the eggs on them gradually enter the detection range of the sensor 22. Due to the structure of the egg claws 52 and the eggs, the center point of the egg must be between the two egg claws 52 (as shown by Y1, Y2, or Y3 in the figure). The three eggs in the figure represent eggs of different sizes, shapes, or placement positions. All sensors 22 can be regarded as a sensing line B. Whenever an egg hits the line, the sensing line must be triggered first at point Y1, Y2, or Y3, that is, the sensor 22 at point Y1, Y2, or Y3 is triggered first. As the egg claws 52 continue to move, their adjacent X1, X2, X3, Z1, Z2, Z3 are triggered later.

[0039] To avoid the sensors 22 at points X, Y, and Z repeatedly counting the same egg, a very short variable time t0 is named the "hitting the line interval." This embodiment uses a hitting the line interval t0 of 150 milliseconds as an example. When any sensor 22 of each row of egg claws 52 is triggered (Y3 is triggered first in the diagram), the hitting the line interval t0 begins timing. In this embodiment, the timing is 150 milliseconds. Within the hitting the line interval t0, all triggered sensors 22 (Y1, Y2, and Y3 in the diagram) are considered to be at point Y, indicating that this point might be an egg. When the hitting the line interval t0 ends, any sensor 22 triggered at this point is considered to be at point X or Z, without any further determination logic.

[0040] To avoid false triggering, point Y proceeds to the next step of the judgment. For each sensor 22 (i.e., point Y) that triggers within the collision interval t0, the trigger duration must satisfy time t1. We call this time t1 the timing length, which in this embodiment is 400 milliseconds. That is, after the corresponding sensor 22 is triggered, when it no longer senses an egg, the sensor 22 stops triggering and sets. The time from triggering to setting must exceed the timing length t1; otherwise, the number of eggs is incremented by 1. Invalid time is not counted.

[0041] When the egg is in an upright position, as shown in the diagram (the third egg at position Y3), the upright egg is relatively long, so the sensor 22 at position Y3 will be in the triggered state for a long time. This will affect the counting of the next layer of egg claws 52 when they come over. Therefore, the sensor 22 needs to be set with an upper limit for the trigger time. When the sensor 22 reaches the upper limit for the trigger time, the sensor 22 will stop triggering and be set, and then the number of eggs will be incremented by 1.

[0042] Additionally, when the timing for the crossing interval t0 begins, another timing mechanism, named round time t2, also starts simultaneously. In this embodiment, round time t2 is set to 1000 milliseconds. When round time t2 is reached, the current round of counting ends. The current round of counting also ends when none of the sensors 22 have detected any object, and the system waits for the next row of eggs to arrive.

[0043] The lengths of the collision interval t0, timing length t1, and one-round time t2 are set reasonably according to the different lifting speeds of the egg elevator from the equipment manufacturer. However, it must be ensured that the upper limit of the trigger time is greater than the timing length t1, but less than or equal to the difference between one-round time t2 and the collision interval t0.

[0044] like Figure 5 As shown, a counting method for a vertical egg counting device based on multiple sensors includes the following steps:

[0045] S1. The position of the egg is detected by a sensor array arranged along the movement direction of the egg claw 52, ​​wherein the sensor 22 is configured to form a sensing line B;

[0046] S2. When any sensor 22 is triggered, the collision interval t0 and one round of time t2 are started simultaneously, and all triggered sensors are identified as suspected eggs (the Y point mentioned above) within the collision interval t0.

[0047] S3. Verify the trigger duration of each sensor 22 triggered at a suspected egg location: if the trigger duration of sensor 22 exceeds the preset timing length t1, it is determined to be a valid egg, and the egg count is incremented by 1; if the trigger duration of sensor 22 does not exceed the timing length t1, it is determined to be an invalid trigger; in addition, each sensor 22 has a trigger time limit. When the trigger time limit is reached, sensor 22 will also be forcibly stopped from triggering, and the egg count will be incremented by 1.

[0048] The upper limit of the trigger time satisfies: t1≤upper limit of trigger time≤t2-t0;

[0049] S4. When the timer t2 of a round is reached or all sensors stop triggering, the program stops, waits for the next row of eggs to arrive, and then continues with step S1.

[0050] like Figure 6 As shown, a logical framework for a counting process is constructed based on the above steps. Those skilled in the art can adjust the logical framework of the counting process according to the steps.

[0051] T1, Start; Initialize the counting system and wait for egg claw 52 to trigger.

[0052] T2. When any sensor 22 of each row of egg claws 52 is triggered (an egg on any egg claw 52 in this row hits the line), start the line-hitting interval timer t0 and a round timer t2; record the line-hitting time of each egg.

[0053] T3. Determine whether the time of the collision is within the collision interval t0. If it is within the collision interval t0, proceed to the next step. If it is not within the collision interval t0, no further determination is made.

[0054] T4. For each sensor 22 that is triggered within the line-crossing interval t0, determine whether the trigger time limit has been reached. If the trigger time limit has been reached, the sensor is set. If the trigger time limit has not been reached, determine whether the sensor should stop triggering. If the sensor stops triggering, the sensor is set. If the sensor does not stop triggering, continue to determine whether the trigger time limit has been reached. Continue until all sensors are set.

[0055] T5. Record the sensor setting time and determine whether the sensor trigger duration meets the timing length t1. If the sensor trigger duration meets the timing length t1, then increment the number of eggs by 1; otherwise, it is an invalid time and no count is made during the invalid time.

[0056] T6. After the timing in S2 starts, determine whether a round time t2 has been reached. If it has, end the process. If not, determine whether all sensor triggers have ended. If the sensor triggers have ended, end the process. If the sensor triggers have not ended, continue to determine whether a round time t2 has been reached until the process ends.

[0057] Example 2:

[0058] This embodiment is a further improvement on Embodiment 1.

[0059] like Figure 4 As shown, to reduce the possibility of the sensor 22 being accidentally touched by feathers or dust, a nozzle 23 is also fixed on the sensor bracket 21, and the nozzle 23 is connected to an air supply device. The nozzle 23 sprays air upwards and is located at the front end of the sensor's emitting end. By setting the nozzle, air can be blown onto the emitting end of the sensor 22, thereby forming an airflow isolation, reducing the probability of dust or feathers passing through or falling onto the sensor 22 from the front end of the sensor, causing long-term obstruction, and reducing the possibility of it being falsely triggered.

[0060] Based on sensor trigger and cutoff signals and multiple timers for judgment and counting, it can accurately record the number of eggs in each egg collection elevator and view historical records on the controller, providing strong support for the modern statistical management of farms.

[0061] Of course, the above description is not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by counters in the field of counters within the scope of the present invention should also fall within the protection scope of the present invention.

Claims

1. A vertical egg counting device with multiple sensors, characterized in that: It includes a mounting frame, sensor assemblies mounted side-by-side on the mounting frame, and a controller that is signal-connected to the sensor assemblies; The fixing frame is fixed to the vertical egg collecting elevator and is located above the egg drop opening of the vertical egg collecting elevator, and it spans the vertical egg collecting elevator. The sensor assembly includes a sensor bracket fixed on the fixed frame and a sensor mounted on the sensor bracket; a set of the sensor assembly is provided for each egg claw gap, and the sensor illuminates the egg claw gap of the vertical egg collecting elevator; the sensor signal is connected to the controller, and the controller is located on one side of the vertical egg collecting elevator; The controller is configured to perform the following counting method: S1. Detect the position of the egg using a sensor array; S2. When any of the sensors is triggered, the collision zone and a timer are started simultaneously, and the egg claw gaps corresponding to all the triggered sensors are identified as suspected eggs within the collision zone. S3. Verify the trigger duration of the sensor triggered at each suspected egg location: if the sensor trigger duration exceeds the preset timing length, it is determined to be a valid egg, and the egg count is incremented by 1; if the sensor trigger duration does not exceed the timing length, it is determined to be an invalid trigger. When each sensor has a trigger time limit, the sensor will be forcibly stopped triggering when the trigger time limit is reached, and the egg count will be incremented by 1. The upper limit of the trigger time satisfies: timing length ≤ upper limit of trigger time ≤ one round time - the boundary interval; S4. When the timer expires, the program stops, waits for the next row of eggs to arrive, and then continues with step S1.

2. The vertical egg counting device with multiple sensors according to claim 1, characterized in that: A nozzle is also fixed on the sensor bracket. The nozzle is connected to an air supply device. The nozzle sprays air upwards and is located at the front end of the sensor's transmitting end.

3. The vertical egg counting device with multiple sensors according to claim 1, characterized in that: The S4 also includes the following condition: the program stops when all sensors stop triggering.

4. The vertical egg counting device with multiple sensors according to claim 3, characterized in that: Construct a logical framework for a counting process; The process includes the following steps: T1, Start; T2. When any sensor is triggered, start the timer for the crossing section and start a round of timer; record the crossing time of each egg; T3. Determine whether the time of the finish line is within the finish line interval; If it is within the boundary zone, proceed to the next step of the judgment; If the boundary is not within the boundary zone, no judgment logic is performed; T4. For each sensor that is triggered within the collision zone, determine whether the trigger time limit has been reached. If the trigger time limit has been reached, the sensor is set. If the trigger time limit has not been reached, then determine whether the sensor has stopped triggering. If the sensor has stopped triggering, then the sensor is set. If the sensor has not stopped triggering, then continue to determine whether the trigger time limit has been reached. Until all sensors are set; T5. Record the sensor setting time and determine whether the sensor trigger duration meets the timing length. If the sensor trigger duration meets the timing length, increment the number of eggs by 1; otherwise, it is an invalid time and no count is made during invalid time. T6. After the timing in S2 starts, determine whether a round of time has been reached. If it has, end the process. If not, determine whether all sensor triggers have ended. If the sensor triggers have ended, end the process. If the sensor triggers have not ended, continue to determine whether a round of time has been reached until the process ends.

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