An automatic pick-and-place system

Abstract

The application relates to the technical field of food processing automation, and discloses an automatic grabbing, placing and whole-machine system, which comprises a visual identification mechanism, a steaming trolley lifting chuck mechanism, an automatic grabbing and sorting mechanism, an automatic placing mechanism, an automatic tearing and replacing mechanism and an empty tray automatic recycling mechanism. The visual identification mechanism identifies the positions of articles through a visual camera and feeds back; the steaming trolley lifting chuck mechanism adjusts the height of a steaming trolley and draws out a steaming tray; the automatic grabbing and sorting mechanism grabs articles and sorts them; the automatic placing mechanism completes article placing and full-tray pushing out; the automatic tearing and replacing mechanism conveys a tray box; and the empty tray automatic recycling mechanism recycles empty trays. The system realizes automatic identification, grabbing, placing and empty-tray recycling of articles, greatly reduces manual operation, improves the operation efficiency of a production line, guarantees production continuity, avoids manual operation errors, improves article placing precision and quality stability, and reduces production cost.

Description

Technical Field

[0001] This invention belongs to the field of food processing automation technology, specifically relating to an automatic gripping and tray feeding system. Background Technology

[0002] In the large-scale production processes of foods such as steamed buns, cakes, and mooncakes, the process of picking and placing food into trays is a core step connecting product cooking with subsequent packaging and warehousing, directly impacting production line efficiency and product quality control. Currently, most companies in the industry still use traditional manual operation methods to complete this process. For example, when producing steamed buns, workers must manually pick up the cooked items one by one from the steaming trays and place them into trays. Simultaneously, manual labor is required to move the steaming cart, collect empty steaming trays, and manually replenish trays. This manual operation method is no longer suitable for the modern food production demands for high efficiency, standardization, and low cost, becoming a key bottleneck restricting production line capacity improvement and quality stability.

[0003] While some companies have attempted to introduce simple automated devices to optimize certain processes, such as using fixed mechanical grippers to replace manual handling or simple conveyor belts to transport steaming trays, these devices have significant limitations. In terms of functional integration, existing devices are mostly designed for single processes and cannot achieve coordinated operation across the entire process, including steam cart lifting, tray extraction, item identification and positioning, material sorting, tray tearing and replenishment, and empty tray recycling. Manual coordination is still required for tray transport and item handling, as well as tray replenishment and placement, creating "automation islands" and failing to fundamentally reduce human intervention. Furthermore, the shortcomings of existing technologies are further highlighted in terms of production efficiency and quality assurance. Under manual operation, operators are affected by physiological limits and fatigue, resulting in a tray handling efficiency of only 300-500 trays per hour, which decreases significantly with increasing working hours. Time gaps exist between processes, making continuous production difficult.

[0004] In view of this, we propose an automatic gripping and tray loading system to solve the above problems. Summary of the Invention

[0005] The present invention aims to solve the technical problem that the existing technologies rely heavily on manual labor for tasks such as grabbing and placing trays, transporting steaming carts, and recycling empty trays. This is labor-intensive and prone to fatigue, which leads to a decline in production efficiency over time. As a result, it is difficult to meet the needs of large-scale production and cannot achieve the technical problem of fully integrated operation of steaming tray extraction, item identification, tray replenishment, and empty tray recycling.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] An automatic gripping and tray loading system includes:

[0008] The visual recognition mechanism uses a visual camera to look down, and the visual contour on the visual camera covers the grasping position, which is used to identify the position of the object and feed it back to the robot control system.

[0009] The steaming cart lifting and clamping mechanism includes a steaming cart lifting module and a clamping plate lifting module. The steaming cart lifting module is used to adjust the height of the steaming cart, and the clamping plate lifting module pulls the steaming plate out of the steaming cart.

[0010] The automatic gripping and sorting mechanism uses a collaborative robot A to drive a row of gripping fixtures to grab items from the steaming trays and place them into a multi-column powered sorting line. The multi-column powered sorting line automatically sorts the items and outputs them in an orderly single row.

[0011] The automatic tray loading mechanism includes a collaborative robot B, a tray loading conveyor belt, a variable pitch gripper, a pneumatic pressing mechanism, and a pneumatic pushing mechanism. The collaborative robot B carries the variable pitch gripper to grab and, together with the pneumatic pressing mechanism, loads the tray into the tray. The pneumatic pushing mechanism then pushes out the full tray.

[0012] The automatic tray tearing and replenishing mechanism outputs the tray to the tray insertion position through the cooperation of the tray supply belt, the lifting tray supply module and the tray tearing module;

[0013] The automatic empty disc recycling mechanism automatically recycles empty discs that have been used to grab items by working together with a double clamping line, an empty disc lifting module, and a recycling vehicle.

[0014] Preferably, the vision camera is mounted and fixed to the top of the frame via a camera mount that is fixedly connected to it.

[0015] Preferably, the steaming cart lifting module includes a gear and rack linear module fixed to the frame. The lifting support of the gear and rack linear module is equipped with a lifting bracket. The movement of the gear and rack linear module drives the lifting bracket to lift and lower, thereby lifting and lowering the steaming cart placed on the lifting bracket, while ensuring the horizontality of the lifting.

[0016] Preferably, the clamping plate lifting module is located to the left of the steaming cart lifting module and fixed in the middle of the frame. The horizontal linear module on the clamping plate lifting module moves the clamping plate assembly and clamps or pulls the steaming plate, transferring the steaming plate from the steaming cart to two sets of belt conveyor modules. The two sets of belt conveyor modules then transport the entire plate.

[0017] Preferably, the automatic tray tearing and replenishing mechanism includes a tray supply belt connected to the frame, a lifting tray supply module installed on the frame, and a tray tearing module. The tray is manually placed onto the tray supply belt, the lifting tray supply module is raised to the tray tearing position, and the tray tearing module automatically tears the tray and outputs the tray individually to the tray entry position. After the full tray is pushed out, the empty tray is replenished.

[0018] Preferably, the lifting and feeding module includes a vertical screw linear module fixedly mounted on the frame and a receiving box conveyor belt mounted on the lifting seat of the vertical screw linear module. The vertical screw linear module moves to lift the receiving box conveyor belt, thereby transporting the box to the tearing station.

[0019] The tray-tearing module includes a transverse lead screw linear module fixedly mounted on the frame, a downward cylinder mounted on the translation seat of the transverse lead screw linear module, a downward plate fixedly connected to the end of the piston rod of the downward cylinder, and a vacuum suction cup fixed on the downward plate for picking up the tray. At least two vacuum suction cups are provided. The transverse lead screw linear module works in conjunction with the vacuum suction cups to transfer the tray from the stow station to the tray-feeding station.

[0020] Preferably, the collaborative robot A on the automatic gripping and feeding mechanism is centrally mounted on the frame and located on one side of the vision recognition mechanism.

[0021] As a preferred embodiment, the automatic empty tray recycling mechanism includes a double clamping line, an empty tray lifting module, and a recycling vehicle. The recycling vehicle is installed on the cantilever of the empty tray lifting module. The empty tray is lifted and recycled with four-way limit. When the empty tray has finished grabbing items, it falls into the recycling vehicle when the double clamping line is open. The empty tray lifting module descends one position, and a full steaming tray takes its place.

[0022] Preferably, collaborative robot B is fixed above the side of the frame, a variable pitch clamp is installed at the flange of collaborative robot B, the loading conveyor is installed in the middle of the frame, the pneumatic pressing mechanism is fixed above the loading position, and a pneumatic pushing mechanism is installed on the side.

[0023] The tray conveyor receives individual trays from the automatic tray tearing and replenishing mechanism, stably transporting the trays to the preset tray placement position, providing a stable working platform for the collaborative robot B, which carries a variable-pitch gripper and works with a pneumatic pressing mechanism to complete the tray placement.

[0024] Compared with the prior art, the technical effects and advantages of the present invention are:

[0025] The automated grabbing and tray-loading system achieves full-process automation through the coordinated operation of six core mechanisms. The operator manually pushes the steaming cart containing the steaming trays to the steaming cart lifting and clamping mechanism. The steaming cart lifting module adjusts the height of the steaming cart, and the clamping lifting module pulls out the steaming trays and transports them to the double clamping line for positioning. The vision recognition mechanism identifies the position of the items in the steaming trays through a vision camera and feeds it back to the robot control system. Collaborative robot A carries a row of gripping fixtures to grab the items and place them into multiple rows of powered material handling lines. The material handling lines arrange the items into a single row for orderly output. At the same time, the automatic tray tearing and replenishing mechanism transports individual trays to the receiving position through the tray supply belt, lifting supply module, and tearing module. Collaborative robot B carries variable pitch grippers to grab the sorted items and, in conjunction with the pneumatic pressing mechanism, completes the tray placement. The pneumatic pushing mechanism pushes out full trays and is filled by empty trays. The empty trays, after grabbing the items, are released through the double clamping line and fall into the recycling cart. The empty tray lifting module drives the recycling cart to descend, and full steaming trays are simultaneously replenished. The operation is completed in a cycle, during which only manual intervention is required for steaming cart replacement, recycling cart emptying, and intermittent tray replenishment.

[0026] Compared to existing technologies that rely on manual handling or only partially automated systems, this system employs a highly integrated automation design, covering the entire process from tray extraction, item identification and handling, material sorting, to tray tearing and replacement, item placement, and empty tray recycling, significantly reducing manual intervention. Existing technologies require manual handling of items, placement of trays, transport of steaming carts, and empty tray recycling, which is not only labor-intensive but also prone to disruptions in process flow due to human fatigue. In contrast, this system achieves seamless integration of each step through the linkage of various mechanisms, eliminating the need for frequent manual switching between multiple processes, significantly improving the overall continuity of the production line and avoiding production capacity waste caused by gaps in manual operation.

[0027] Existing technologies often suffer from uneven gripping force leading to deformation, disorganized tray placement, and hygiene hazards due to human contact. Furthermore, simple automated systems lack precise identification and adaptation capabilities, making them incompatible with products of different sizes. This new system uses visual recognition to precisely locate items, a collaborative robot with specialized grippers achieves stable gripping, and a pneumatic pressing mechanism ensures neat placement of items, reducing product quality loss. The variable-pitch gripper and adjustable modules allow for adaptation to different item and tray sizes, enhancing the system's flexible production capabilities. In addition, the system reduces reliance on manual labor, lowering labor costs, and avoids issues such as missed or incorrect loading due to human error, indirectly reducing production costs and meeting the standardization and intelligentization requirements of modern food production. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the structure of the present invention;

[0029] Figure 2 This is the front view of the present invention;

[0030] Figure 3 This is a top view of the present invention;

[0031] Figure 4 This is the left view of the present invention;

[0032] Figure 5 This is a schematic diagram of the structure of the visual recognition mechanism of the present invention;

[0033] Figure 6 This is a schematic diagram of the structure of the steaming cart lifting clamping plate mechanism of the present invention;

[0034] Figure 7 This is a front view of the steamer lifting clamping mechanism of the present invention;

[0035] Figure 8 This is a schematic diagram of the automatic material handling mechanism of the present invention;

[0036] Figure 9 This is a schematic diagram of the automatic tray placement mechanism of the present invention;

[0037] Figure 10 This is a schematic diagram of the automatic tearing and patching mechanism of the present invention;

[0038] Figure 11 This is a schematic diagram of the structure of the automatic empty disk recycling mechanism of the present invention.

[0039] In the picture:

[0040] 1. Visual recognition mechanism; 11. Visual camera; 12. Visual profile; 13. Camera mount;

[0041] 2. Steaming cart lifting clamp mechanism; 21. Steaming cart lifting module; 2101. Gear and rack linear module; 2102. Lifting bracket; 22. Clamp lifting module; 2201. Transverse linear module; 2202. Clamp assembly; 2203. Belt conveyor module;

[0042] 3. Automated material handling and feeding mechanism; 31. Collaborative robot A; 32. Row of gripping fixtures; 33. Multi-row powered material handling line;

[0043] 4. Automated tray loading mechanism; 41. Collaborative robot B; 42. Tray loading conveyor belt; 43. Variable pitch clamp; 44. Pneumatic pressing mechanism; 45. Pneumatic box pushing mechanism;

[0044] 5. Automatic tray tearing and replenishing mechanism; 51. Tray supply conveyor belt; 52. Lifting tray supply module; 53. Tray tearing module; 54. Vertical lead screw linear module; 55. Lifting seat; 56. Tray receiving box conveyor belt; 57. Horizontal lead screw linear module; 58. Translation seat; 59. Downward cylinder; 510. Downward plate; 511. Empty suction cup;

[0045] 6. Automatic empty tray recycling mechanism; 61. Double clamping line; 62. Recycling vehicle; 63. Empty tray lifting module;

[0046] 7. Steaming cart; 8. Machine frame. Detailed Implementation

[0047] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0048] The following combination Figures 1 to 11 This application will be described in further detail;

[0049] This automatic gripping and tray-feeding system is a highly integrated and automated food processing system. It is mainly used for the automatic identification, gripping, sorting, tray feeding, and auxiliary operations of items. The core system consists of six major mechanisms: a vision recognition mechanism 1, a steaming cart lifting and clamping mechanism 2, an automatic gripping and sorting mechanism 3, an automatic tray feeding mechanism 4, an automatic tray tearing and replenishing mechanism 5, and an automatic empty tray recycling mechanism 6. These mechanisms are precisely installed and work together through the frame 8. The system can complete the entire automated operation from the extraction of steaming trays from the steaming cart 7, the identification and gripping of items, to the tray tearing and replenishing, the feeding of items, and the recycling of empty trays. This greatly reduces manual intervention and improves production efficiency and product quality stability.

[0050] The core component of the visual recognition mechanism 1 is the visual camera 11, which has a visual contour 12 for defining the recognition range. The visual camera 11 is fixed to the top of the frame 8 by a camera mounting base 13 that is fixedly connected to it. The top mounting method ensures that the visual camera 11 is installed firmly and has an unobstructed field of view.

[0051] The vision camera 11 operates by illuminating downwards, and its visual contour 12 can completely cover the object grasping position, enabling it to take pictures of the items in the steaming tray that are transported to the positioning position. Through image algorithms, it accurately identifies the actual position, quantity, and distribution of the items within the visual contour 12 range, and feeds this key information back to the robot control system in real time, providing data support for the subsequent accurate grasping of the collaborative robot, avoiding missed or incorrect grasping, and ensuring grasping accuracy.

[0052] Compared to manual visual positioning, the visual recognition mechanism 1 has a fast recognition response speed (single recognition time ≤ 0.5 seconds) and high positioning accuracy (positioning error ≤ ±1 mm). It can adapt to the scenario where items are randomly distributed in the steaming tray, providing a reliable positioning basis for the automated grasping process and reducing the problem of item deformation or falling off due to inaccurate positioning.

[0053] The steam cart lifting and clamping mechanism 2 is mainly used to realize the height adjustment of the steam cart 7 and the automatic extraction and conveying of the steaming trays. It consists of the steam cart lifting module 21 and the clamping plate lifting module 22.

[0054] The steam cart lifting module 21 includes a gear and rack linear module 2101 that is fixed against the frame 8. The lifting support of the gear and rack linear module 2101 is provided with a lifting bracket 2102. The gear and rack linear module 2101 drives the lifting bracket 2102 to lift and lower, thereby lifting and lowering the steam cart 7 placed on the lifting bracket 2102, while ensuring the horizontality of the lifting.

[0055] The core function of the steam cart lifting module 21 is to adjust the height of the steam cart 7 to match the tray-pulling position of the clamping plate lifting module 22. During operation, the gear and rack linear module 2101 is energized, which drives the lifting support and the lifting bracket 2102 installed on it to slide up and down. The steam cart 7 is placed on the lifting bracket 2102 and rises and falls synchronously with the lifting bracket 2102, so that the steaming tray inside the steam cart 7 is aligned with the gripping position of the clamping plate lifting module 22.

[0056] The clamping plate lifting module 22 is located to the left of the steaming cart lifting module 21 and fixed in the middle of the frame 8. The horizontal linear module 2201 on the clamping plate lifting module 22 moves the clamping plate assembly 2202 to clamp or pull the steaming plate, and transfers the steaming plate from the steaming cart 7 to the two sets of belt conveyor modules 2203. The two sets of belt conveyor modules 2203 move to transport the entire plate.

[0057] When the two belt conveyor modules 2203 are powered on, they stably transport the steaming trays placed on them to the double clamping line 61 for positioning, in preparation for subsequent visual recognition and grasping.

[0058] The automatic gripping and material handling mechanism 3 includes a collaborative robot A31, a row of gripping fixtures 32, and a multi-row powered material handling line 33. The collaborative robot A31 is centrally mounted on the frame 8 and located on one side of the vision recognition mechanism 1, and is installed by hanging or fixing. The row of gripping fixtures 32 is mounted on the flange of the collaborative robot A31 and can be replaced according to the specifications of the items. The multi-row powered material handling line 33 is mounted in the middle of the frame 8 and is located within the working range of the collaborative robot A31.

[0059] The core function of the automatic gripping and sorting mechanism 3 is to automatically grip and sort items. During operation, the collaborative robot A31 receives the item position information from the visual recognition mechanism 1 and moves the entire row of gripping fixtures 32 above the steaming tray. It grips the items on the steaming tray by opening and closing the fixtures (it can grip multiple rows of items at a time, and the number of items gripped is adjusted according to the fixture specifications), and transfers the gripped items to the multi-row powered sorting line. The multi-row powered sorting line automatically sorts the disordered items through the speed difference of the multi-row conveyor belts or the guide structure, and finally achieves the output of items in a single row, in an orderly manner, with uniform spacing, in preparation for the subsequent automatic tray loading process.

[0060] Collaborative robot A is highly maneuverable (repeat positioning accuracy ≤ ±0.1mm) and fast grasping speed (single grasping cycle ≤ 2 seconds), improving grasping efficiency by 3 to 5 times compared to manual single-item grasping. The entire row of grasping fixtures can be replaced according to the diameter of the items (range 50~100mm) to adapt to different product specifications. The multi-row powered material handling line 33 has high material handling efficiency (material handling speed ≤ 300 items / minute), and the spacing deviation of the items after material handling is ≤ ±2mm, avoiding the messiness problem of manual material handling and laying the foundation for accurate subsequent placement.

[0061] The automatic palletizing mechanism 4 includes a collaborative robot B41, a palletizing conveyor belt 42, a variable-pitch gripper 43, a pneumatic pressing mechanism 44, and a pneumatic pushing mechanism 45. The collaborative robot B41 is fixed above the side of the frame 8, and a variable-pitch gripper 43 (a 4X5 specification variable-pitch gripper is used in this system) is installed at its flange, which can grasp 20 items at a time. The palletizing conveyor belt 42 is installed in the middle of the frame 8 for conveying pallets. The pneumatic pressing mechanism 44 is fixed above the palletizing position for assisting in palletizing. The pneumatic pushing mechanism 45 is installed on the side of the palletizing position for pushing full pallets.

[0062] The automatic loading mechanism 4 is the core component for loading items into the container. Its specific workflow is as follows:

[0063] The tray conveyor 42 receives a single tray from the automatic tray tearing and replenishing mechanism 5 and stably transports the tray to the preset tray position, providing a stable working platform for the tray loading operation of the collaborative robot B41.

[0064] The collaborative robot B41 drives the variable-pitch gripper 43 to move to the output end of the multi-column power feeding line 33, and grabs a single row of items after feeding. The variable-pitch gripper 43 can automatically adjust the gripping distance according to the preset arrangement spacing of the items in the tray, such as 4 columns and 5 rows, so that the spacing of the items matches the grid position in the tray.

[0065] Collaborative robot B41 moves the grasped item to the upper part of the tray and aligns the item with the inner compartment of the tray. At this time, the pneumatic pressing mechanism 44 is activated, and the cylinder pushes the pressing head to gently press down on the item, helping the item to be placed smoothly into the tray and avoiding the item's softness from shifting or getting stuck.

[0066] When the tray is filled with items (according to the preset quantity, such as 20 items), the pneumatic pusher mechanism 45 moves to push the full tray out from the tray entry position and transport it to the subsequent packaging stage. At the same time, the empty tray is replaced by the automatic tray tearing and replenishing mechanism 5 and placed in the tray entry position, waiting for the next tray entry.

[0067] The automatic tray-tearing and replenishing mechanism 5 is a key mechanism to ensure a stable supply of trays and enable continuous operation in the tray placement process. Its core consists of three parts: a tray supply conveyor belt 51, a lifting tray supply module 52, and a tray-tearing module 53. Each component is precisely installed and operates in coordination with the frame 8. The specific structure and installation details are as follows:

[0068] The pallet supply belt 51 is connected to the frame 8 and adopts a belt conveyor structure. It serves as the initial supply and conveying channel for pallets. Manual personnel can directly place stacked empty pallets on its conveyor belt. The rotation of the belt will transport the pallets in batches to the working area of ​​the lifting pallet supply module 52, providing a stable source of pallets for subsequent pallet tearing operations.

[0069] The lifting and feeding module 52 is installed on the frame 8. Its core consists of a vertical lead screw linear module 54 and a receiving box conveyor belt 56. The vertical lead screw linear module 54 is fixedly installed on the frame 8, and its main body is rigidly connected to the frame 8 with bolts to ensure no shaking or deviation during the lifting process. The receiving box conveyor belt 56 is installed on the lifting seat 55 of the vertical lead screw linear module 54. It moves up and down synchronously with the lifting seat 55. It can receive the stacked boxes conveyed by the feeding conveyor belt 51 and lift the boxes to the tearing station height that is compatible with the tearing module 53.

[0070] The tray-tearing module 53 is fixedly installed on the side of the frame 8. Its core consists of a transverse lead screw linear module 57, a downward cylinder 59, a downward plate 510, and a vacuum suction cup 511. The transverse lead screw linear module 57 is fixedly installed on the frame 8, and its main body is fastened to the side crossbeam of the frame 8 via a flange to ensure stability during transverse movement. The downward cylinder 59 is installed on the translation seat 58 of the transverse lead screw linear module 57, moving horizontally with the translation seat 58. The downward plate 510 is fixedly connected to the piston rod end of the downward cylinder 59, allowing for vertical lifting and lowering under the drive of the downward cylinder 59. The vacuum suction cup 511 is fixed on the downward plate 510 and used to lift the tray; at least two vacuum suction cups 511 are provided (see attached diagram). Figure 10 (The default configuration has 4 units, arranged in a rectangular pattern) to ensure uniform adsorption force on the tray and prevent the tray from tilting or falling off.

[0071] The core function of the automatic tray tearing and replenishing mechanism 5 is to individually separate (tear) stacked empty trays and accurately transport them to the tray insertion position. At the same time, it promptly replenishes empty trays after full trays are pushed out. The specific workflow and action logic are as follows:

[0072] Manually place the pallet boxes onto the pallet supply belt 51. The pallet supply belt 51 is started and transports the stacked pallets to the pallet receiving belt 56 of the lifting pallet supply module 52 via belt conveyor. The pallet receiving belt 56 runs briefly to align the stacked pallets, ensuring that the pallets are stacked neatly, laying the foundation for the accuracy of the subsequent pallet tearing action.

[0073] The vertical lead screw linear module 54 of the lifting and feeding module 52 is activated, driving the lifting seat 55 and the receiving box belt 56 mounted on it to rise synchronously. According to the preset tearing height of the tearing module 53, the stacked boxes are lifted to the tearing position (i.e., the height that the vacuum suction cup 511 can accurately pick up). During the lifting and feeding process, the transmission accuracy of the vertical lead screw linear module 54 can ensure that the error of the box lifting and feeding height is ≤ ±0.3mm, ensuring that the box position is consistent after each lifting and feeding.

[0074] When the tearing and traying module 53 starts operating, the piston rod of the downward cylinder 59 extends, driving the downward plate 510 and the vacuum suction cup 511 to descend vertically until the vacuum suction cup 511 makes close contact with the surface of the top tray of the stacked trays. Then, the vacuum system starts, and the vacuum suction cup 511 generates negative pressure to firmly suck up the top tray. Next, the piston rod of the downward cylinder 59 retracts, driving the adsorbed tray to rise vertically and completely separate from the lower stacked trays, realizing the individual tearing and separation of the tray. Finally, the horizontal lead screw linear module 57 moves, driving the translation seat 58 and the vacuum suction cup 511 adsorbing the tray to move horizontally, transferring the tray from the tearing and traying station (above the original lifting and traying module 52) to the traying station (i.e., the feeding end of the traying conveyor belt 42). After reaching the traying station, the vacuum system stops working, the vacuum suction cup 511 releases the tray, and the tray is placed stably on the traying conveyor belt 42, completing the output of a single tray.

[0075] When the pneumatic pusher mechanism 45 of the automatic tray loading mechanism 4 pushes the full tray filled with items out of the tray loading position, the tray loading belt 42 starts and stably transports the new empty tray from the tray tearing module 53 to the preset tray loading position, realizing the automatic replenishment of empty trays and ensuring that there are always trays waiting for items to be loaded at the tray loading station, without any process interruption gaps.

[0076] Through the coordinated operation of the pallet feeding belt 51, the lifting pallet feeding module 52, and the pallet tearing module 53, the entire process of pallet feeding, from manual replenishment to individual output and automatic replenishment, is fully automated. There is no need for manual placement of pallets one by one. It can complete the tearing and supply of 240 to 300 pallets per hour, which is 3 to 4 times more efficient than manual pallet tearing and replenishment, and effectively avoids production line shutdowns caused by untimely manual pallet replenishment.

[0077] The automatic empty tray recycling mechanism 6 is a key mechanism for automatically recycling empty steaming trays after they have been used to pick up items, preventing empty trays from accumulating and occupying production space, and ensuring a continuous supply of steaming trays. Its core consists of three parts: a double clamping line 61, an empty tray lifting module 63, and a recycling vehicle 62. Each component works precisely in sync with the process of "empty tray falling – recycling – full tray transfer." The specific structure and installation details are as follows:

[0078] The automatic empty tray recycling mechanism 6 includes a double clamping line 61, an empty tray lifting module 63, and a recycling cart 62. The double clamping line 61 is centrally installed below the middle area of ​​the frame 8, at the end of the steaming tray conveying path. It adopts two sets of symmetrical clamping belt structures to achieve temporary clamping, positioning, and release of the steaming trays. The empty tray lifting module 63 is fixed against the frame 8, and its main body is fastened to the bottom column of the frame 8 with bolts to ensure the levelness during the lifting process (horizontal deviation ≤ ±0.5mm). The recycling cart 62 is mounted on the cantilever of the empty tray lifting module 63. The recycling cart 62 is equipped with limiting structures such as angle steel limiting blocks around its perimeter to prevent the empty trays from slipping out of the recycling cart during the lifting and recycling process. At the same time, the recycling cart 62 and the cantilever are connected by a snap-fit, which facilitates quick separation and repositioning when manually pulled out.

[0079] The core function of the automatic empty tray recycling mechanism 6 is to automatically collect and recycle empty steaming trays after the automatic grabbing and sorting mechanism 3 has grabbed the items, and to replenish full steaming trays in accordance with the steaming tray supply rhythm. The specific workflow and action logic are as follows:

[0080] Once the items in the steaming tray have been completely gripped by the collaborative robot A31 carrying the entire row of gripping clamps 32, the dual clamping lines 61 that were originally used to hold and position the steaming tray will start to release. The two sets of clamping belts will rotate in opposite directions or open outwards, releasing the clamping constraint on the empty tray. Under its own gravity, the empty tray will fall from the clamping area of ​​the dual clamping lines 61 into the recycling vehicle 62 below, completing the initial recycling of the empty tray.

[0081] Each time an empty tray falls into the recycling vehicle 62, the empty tray lifting module 63 activates once, causing its cantilever and the recycling vehicle 62 to descend one position simultaneously (the descent height is adapted to the thickness of a single steaming tray, usually 15-20mm), ensuring that the top of the empty tray stack inside the recycling vehicle 62 always maintains a suitable distance (30-50mm) from the drop opening of the double clamping line 61, avoiding subsequent empty trays from violently colliding with the already stacked empty trays, causing damage or displacement.

[0082] While the empty tray lifting module 63 lowers the recycling vehicle 62, the tray lifting module 22 of the steaming vehicle lifting and clamping mechanism 2 has transported the new full steaming tray (containing ungrabbed items) to the double clamping line 61 via the belt conveyor module 2203. The double clamping line 61 restarts its clamping action to clamp and position the new full steaming tray, completing the automatic replenishment of the full steaming tray. This ensures that the visual recognition mechanism 1 and the automatic gripping and sorting mechanism 3 can continuously perform item recognition and gripping operations without any gaps in the supply of steaming trays.

[0083] As the system continues to operate, the empty trays inside the recycling truck 62 accumulate. When the recycling truck 62 is full of empty trays (usually accommodating 20-30 empty trays), the system control panel will issue an audible and visual alarm. At this time, the operator can pull the recycling truck 62 out from the cantilever of the empty tray lifting module 63, tilt the empty trays to the designated storage area, and then place the emptied recycling truck 62 back onto the cantilever and secure it with the buckle to complete the emptying operation of the recycling truck and ensure the continuous operation of empty tray recycling.

[0084] Replacing the traditional manual handling of empty trays, the entire process, from release, dropping, and stacking of empty trays to prompting for replacement when the recycling vehicle is full, requires no manual intervention. It can recycle 30-40 empty trays per hour, which is 2-3 times more efficient than manual recycling. At the same time, it avoids damage to the steaming trays caused by collisions during manual handling (the empty tray breakage rate is reduced from 5% in manual recycling to below 0.5%), reducing the cost of purchasing and replacing steaming trays for enterprises.

[0085] By coordinating the synchronous descent of the empty tray lifting module 63 with the full steam tray replacement of the double clamping line 61, a seamless connection of "empty tray recycling - full tray replacement" is achieved. The steam tray supply interval is ≤10 seconds, ensuring that the automatic gripping and feeding mechanism 3 and the vision recognition mechanism 1 can operate continuously without the problem of slowing down the production line cycle due to the interruption of steam tray supply, thus indirectly improving the overall production efficiency of the machine.

[0086] The complete workflow of the automatic pallet-grabbing system is as follows:

[0087] Initial preparation and docking with the steaming cart: The steaming cart 7 containing the cooked items is manually pushed to the steaming cart lifting clamping mechanism 2. After the system is started, the steaming cart lifting module 21 drives the lifting bracket 2102 through the gear and rack linear module 2101 to automatically lift the steaming cart 7 according to the tray position of the clamping lifting module 22, so that the steaming tray inside the steaming cart 7 is aligned with the gripping height of the clamping lifting module 22.

[0088] Steaming tray extraction and positioning: The clamping lifting module 22 is activated, and the horizontal linear module 2201 drives the clamping assembly 2202 to move to the steaming tray; the clamping assembly 2202 clamps the steaming tray, and the horizontal linear module 2201 extracts the steaming tray from the steaming cart 7 and transfers it to the belt conveyor module 2203; the belt conveyor module 2203 conveys the steaming tray to the double clamping line 61 to complete the positioning.

[0089] Item recognition and grasping: The vision camera 11 of the vision recognition mechanism 1 takes a downward picture of the steaming tray on the double clamping line 61, identifies the position, quantity and distribution of items within the visual contour 12, and feeds the data back to the robot control system; the collaborative robot A31 receives the instruction, carries the row of grasping grippers 32 to move above the steaming tray, grasps the items and transfers them to the multi-column power sorting line 33; the multi-column power sorting line 33 automatically sorts the items, achieving single-row, orderly and uniformly spaced output.

[0090] Tray tearing and supply: Synchronized with the material handling process, the stacked empty trays are manually placed on the supply belt 51 of the automatic tray tearing and replenishing mechanism 5. The supply belt 51 transports the trays to the receiving tray belt 56 of the lifting supply module 52. The vertical screw linear module 54 drives the lifting seat 55 to raise the trays to the tearing position. The downward cylinder 59 of the tearing module 53 drives the vacuum suction cup 511 to descend and adsorb the top tray. After rising, the trays are transferred to the infeed belt 42 through the horizontal screw linear module 57. The trays are then transported to the preset infeed position via the infeed belt 42.

[0091] Item placement with variable spacing and ejection when full: Collaborative robot B41, carrying variable spacing gripper 43, moves to the output end of multi-row power feeding line 33 to grab a single row of items. The gripper automatically adjusts the spacing to fit the 4x5 compartments of the tray. The robot moves the items to the top of the placement position, and the pneumatic pressing mechanism 44 assists in the smooth placement of the items. When the tray is full, the pneumatic pushing mechanism 45 pushes the full tray to the subsequent packaging stage, while the automatic tray tearing and replenishing mechanism 5 delivers a new empty tray to the placement position to fill the gap.

[0092] Empty tray recycling and circulation operation: After the items in the steaming tray are grabbed, the double clamping line 61 opens, and the empty tray falls into the recycling cart 62 of the empty tray automatic recycling mechanism 6; the empty tray lifting module 63 drives the recycling cart 62 to descend one position, and the belt conveyor module 2203 transports the next full steaming tray to the double clamping line 61 to fill the position, repeating the above steps 2-5.

[0093] Manual assisted replacement: After all the steaming trays in the steaming cart 7 are removed, the empty steaming cart is pushed away manually and replaced with a new steaming cart full of steaming trays; when the recycling cart 62 is full of empty trays, the recycling cart is pulled out and emptied, and then an empty recycling cart is added; when the empty tray box inventory is insufficient, the supply tray belt line 51 is intermittently replenished manually to ensure the continuous operation of the system.

[0094] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automatic gripping and tray loading system, characterized in that, include: The visual recognition mechanism (1) shines downward through the visual camera (11), and the grasping position is covered within the visual contour (12) on the visual camera (11) to identify the position of the object and feed it back to the robot control system. The steaming cart lifting clamping mechanism (2) includes a steaming cart lifting module (21) and a clamping plate lifting module (22). The steaming cart lifting module (21) is used to adjust the height of the steaming cart (7), and the clamping plate lifting module (22) pulls the steaming plate out of the steaming cart (7). Automatic gripping and sorting mechanism (3), on which the collaborative robot A (31) moves to drive the entire row of gripping fixtures (32) to grab the items on the steaming tray and place them into the multi-column power sorting line (33). The multi-column power sorting line (33) automatically sorts the items and outputs them in a single row in an orderly manner. The automatic tray loading mechanism (4) includes a collaborative robot B (41), a tray loading conveyor (42), a variable pitch gripper (43), a pneumatic pressing mechanism (44), and a pneumatic pushing mechanism (45). The collaborative robot B (41) carries the variable pitch gripper (43) to grab and cooperate with the pneumatic pressing mechanism (44) to load the tray, and the pneumatic pushing mechanism (45) pushes out the full tray. The automatic tray tearing and replenishing mechanism (5) outputs the tray to the tray insertion position through the cooperation of the tray supply belt (51), the lifting tray supply module (52) and the tray tearing module (53); The empty disc automatic recycling mechanism (6) automatically recycles the empty discs that have been gripped by items through the cooperation of the double clamping line (61), the empty disc lifting module (63) and the recycling vehicle (62); The automatic tray tearing and replenishing mechanism (5) includes a tray supply belt (51) connected to the frame (8), a lifting tray supply module (52) installed on the frame (8), and a tray tearing module (53). The tray box is manually placed on the tray supply belt (51), the lifting tray supply module (52) is raised to the tray tearing position, and the tray tearing module (53) automatically tears the tray and outputs the tray box one by one to the tray entry position. After the full tray box is pushed out, the empty tray box is replenished. The lifting and feeding module (52) includes a vertical screw linear module (54) fixedly installed on the frame (8) and a receiving box belt line (56) installed on the lifting seat (55) of the vertical screw linear module (54). The vertical screw linear module (54) moves to drive the receiving box belt line (56) to rise and fall, thereby transporting the box to the tearing station. The tearing and traying module (53) includes a transverse lead screw linear module (57) fixedly installed on the frame (8), a downward cylinder (59) installed on the translation seat (58) of the transverse lead screw linear module (57), a downward plate (510) fixedly connected to the piston rod end of the downward cylinder (59), and a vacuum suction cup (511) fixed on the downward plate (510) for picking up the tray. There are at least two vacuum suction cups (511). The transverse lead screw linear module (57) moves in conjunction with the vacuum suction cups (511) to transfer the tray from the tearing and traying station to the traying station.

2. The automatic gripping and tray loading system according to claim 1, characterized in that: The visual camera (11) is mounted and fixed on the top of the frame (8) via a camera mount (13) that is fixedly connected to it.

3. The automatic gripping and tray loading system according to claim 1, characterized in that: The steam cart lifting module (21) includes a gear and rack linear module (2101) fixed on the frame (8). The lifting support of the gear and rack linear module (2101) is provided with a lifting bracket (2102). The gear and rack linear module (2101) drives the lifting bracket (2102) to lift and lower, thereby lifting and lowering the steam cart (7) placed on the lifting bracket (2102) while ensuring the horizontality of the lifting.

4. The automatic gripping and tray loading system according to claim 3, characterized in that: The clamping plate lifting module (22) is located on the left side of the steaming cart lifting module (21) and fixed in the middle of the frame (8). The horizontal linear module (2201) on the clamping plate lifting module (22) moves the clamping plate assembly (2202) to clamp or pull the steaming plate, and pulls the steaming plate out of the steaming cart (7) and transfers it to the two sets of belt conveyor modules (2203). The two sets of belt conveyor modules (2203) move to transport the whole plate.

5. The automatic gripping and tray loading system according to claim 1, characterized in that: The collaborative robot A (31) on the automatic gripping and feeding mechanism (3) is centrally mounted on the frame (8) and located on one side of the visual recognition mechanism (1).

6. The automatic gripping and tray loading system according to claim 1, characterized in that: The automatic empty tray recycling mechanism (6) includes a double clamping line (61), an empty tray lifting module (63), and a recycling cart (62). The recycling cart (62) is installed on the cantilever of the empty tray lifting module (63). The empty tray is lifted and recycled from all sides. When the empty tray has finished grabbing the items, it falls into the recycling cart (62) when the double clamping line (61) is open. The empty tray lifting module (63) descends one position and the full steaming tray fills the gap.

7. The automatic gripping and tray loading system according to claim 1, characterized in that: Collaborative robot B (41) is fixed above the side of the frame (8). A variable pitch clamp (43) is installed at the flange of collaborative robot B (41). The loading conveyor belt (42) is installed in the middle of the frame (8). The pneumatic pressing mechanism (44) is fixed above the loading position. A pneumatic pushing box mechanism (45) is installed on the side. The tray conveyor (42) receives a single tray from the automatic tray tearing and replenishing mechanism (5) and stably transports the tray to the preset tray position, providing a stable working platform for the collaborative robot B (41) to carry the variable pitch clamp (43) and cooperate with the pneumatic pressing mechanism (44) to complete the tray loading.

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