A multi-stage shunt corn kernel breakage detection device and method

Abstract

The application discloses a multi-stage shunting corn kernel crushing detection device and method, and belongs to the field of corn kernel quality detection. The device comprises a shell, a feeding device, a shunting device, a collecting device, a conveying device, a collection control device, a discharging device, a combing device and a strip light source. The feeding device controls the opening and closing of a feeding port. The shunting device performs multi-stage shunting on corn kernel samples. The collecting device is used for quantitatively draining corn kernel materials. The conveying device is used for conveying the corn kernel materials to a specified area. The collection control device is used for controlling the opening and closing of the feeding and discharging ports, the opening and closing of the light source, the conveying of the materials and the image processing of the corn kernels. The discharging device is used for executing the opening and closing of the discharging port. The combing device is used for combing the kernel samples on the conveying device. The strip light source provides uniform illumination for image collection. The application can realize intermittent quantitative sampling and forced shunting of the corn kernels, make the kernels normally distributed in a single layer on the conveying belt, and improve the stability and precision of the visual detection of the kernel crushing.

Description

Technical Field

[0001] This invention belongs to the field of corn kernel quality testing, specifically relating to a multi-stage diversion corn kernel breakage detection device and method. Background Technology

[0002] Corn kernels are highly susceptible to mechanical damage during mechanized harvesting due to friction and collisions between harvesting components, severely impacting harvest quality and efficiency. Therefore, kernel breakage rate has become a crucial indicator of the performance of corn kernel harvesting machinery. Real-time detection of breakage allows for dynamic adjustment of operating parameters of the components during harvesting, achieving efficient and low-loss harvesting of corn kernels. Currently, corn kernel breakage rate detection primarily employs image recognition-based visual inspection methods. However, the high volume and speed of kernels during mechanized harvesting easily lead to sample accumulation and overlap, affecting the accuracy and stability of visual algorithms. Therefore, achieving a quantitative, orderly, and monolayered distribution of kernel samples is of great significance for improving the accuracy and reliability of visual detection of kernel breakage.

[0003] Invention patent CN118225764A describes a device and method for monitoring the impurity content and breakage rate of grains in a harvester's grain bin. This method utilizes a grooved wheel conveyor mechanism to achieve a sparse, single-layer distribution of grains. However, this technology is limited by the volume of the grooved wheel and is only suitable for intermittent feeding with small amounts of material. It struggles to meet the high-throughput detection requirements under mechanized harvesting conditions and is prone to clogging due to material concentration. Invention patent CN112001283A describes an online detection device and method for corn kernel breakage rate, employing a feed trough and a single-layer dispersion plate to achieve single-layer dispersion of corn kernel samples. However, this technology can only passively adjust the corn kernel feeding state, failing to achieve intermittent quantitative sampling. The breakage rate detection results fluctuate significantly and lack stability under complex mechanized harvesting environments. Therefore, developing a compact, stable, and controllable corn breakage detection device and method is of significant application value in improving the accuracy and stability of corn kernel breakage detection under mechanized harvesting conditions. Summary of the Invention

[0004] The purpose of this invention is to provide a multi-stage diversion corn kernel breakage detection device and method. This device, through intermittent quantitative sampling and forced diversion of corn kernels, enables the kernel samples to be distributed in a single layer of normal distribution on the conveyor belt, thereby significantly improving the stability and accuracy of visual detection of kernel breakage.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A multi-stage diversion corn kernel crushing detection device includes a shell, a feeding device, a diversion device, a collecting device, a conveying device, a data acquisition and control device, a discharging device, a combing device, and a strip light source.

[0007] The feeding device is mounted on the housing and is used to open and close the feed inlet;

[0008] The diversion device is located inside the housing and is used to divert corn kernels in multiple stages.

[0009] The collection device is installed on the shell and is used to quantitatively guide the grains discharged from the grain outlet to the feed inlet;

[0010] The conveying device is located inside the housing and is used to transport the grains to the image acquisition area and then to the discharge port.

[0011] The acquisition and control device is located inside the housing and is used to control the opening and closing of the inlet / outlet, the opening and closing of the strip light source, the operation of the conveyor device, and the acquisition and processing of corn kernel images.

[0012] The discharge device is located on the outside of the housing and is used to open and close the discharge port;

[0013] The combing device is located inside the housing and is used to comb the grains on the conveying device to avoid overlapping.

[0014] A strip light source is located inside the housing to provide illumination for image acquisition.

[0015] The housing includes an upper housing, a lower housing, a side wall housing, a connecting plate, vibration damping pads, a connecting vertical plate, a combing horizontal plate, and a connecting horizontal plate. The upper housing and the lower housing are arranged opposite each other, with an inlet and an outlet respectively. The connecting plate has a U-shaped cross-section, and each end face is provided with a press-fit stud. The connecting plate is installed at the connection between the upper housing and the lower housing and is fixed to the inner press-fit stud by bolts to realize the connection between the upper housing and the lower housing. The side wall housing is installed on both sides of the upper housing and the lower housing and is fixed to the side press-fit stud of the connecting plate by bolts. The vibration damping pad is fixed to the outside of the lower housing by bolts. The connecting vertical plate has several slotted holes and is fixed to the inside of the upper housing by L-shaped corner fittings. The combing horizontal plate is fixed to the connecting vertical plate by L-shaped corner fittings, and the connecting horizontal plate is fixed to the slotted holes in the connecting vertical plate by L-shaped corner fittings.

[0016] The feeding device includes a feeding eye bolt, a feeding plate, and a feeding servo motor. The feeding eye bolt is installed on both sides of the feeding port through flange nuts. The feeding plate has short shafts on both sides and is hinged to the feeding eye bolt. The feeding servo motor drives the connecting rod through the servo motor to realize the rotation of the feeding plate, so as to complete the opening and closing of the feeding port.

[0017] The diversion device includes a first damping hinge, a first diversion plate, a second damping hinge, and a second diversion plate. The first damping hinge is bolted to the connecting vertical plate. The first diversion plate is hinged to the connecting vertical plate via the first damping hinge. The first diversion plate has diversion blocks distributed along its width for primary diversion of corn kernels. Its tilt angle is adjusted by the first damping hinge. The second damping hinge is bolted to the inner side of the upper housing. The second diversion plate is hinged to the inner side of the upper housing via the second damping hinge. The second diversion plate has cylindrical protrusions as Galton nails for further diversion of the kernels. Its tilt angle is adjusted by the second damping hinge.

[0018] The collecting device includes a collecting plate, an inclined corner piece, rubber feet, and a drain plate. The collecting plate is bolted to the inclined corner piece at a fixed angle to guide a portion of the grains from the grain outlet to the feed inlet. The inclined corner piece is bolted to the rubber feet, which are bolted to the upper side of the upper housing to absorb the energy transmitted to the detection device by the impact of the grains. The drain plate is bolted to the inclined corner piece and is arranged in a mirror image with the collecting plate to discharge excess grain samples from the detection device.

[0019] The discharge device includes a discharge lifting eye bolt, a discharge plate, and a discharge servo motor. The discharge lifting eye bolt is installed on both sides of the discharge port through flange nuts. The discharge plate has short shafts on both sides and is hinged in the discharge lifting eye bolt. The discharge servo motor drives the connecting rod to rotate the discharge plate and complete the opening and closing of the discharge port.

[0020] The acquisition and control device is an image acquisition development board with a camera, used to control the angles of the feeding servo motor and the discharging servo motor, the conveying speed of the conveying device, and the opening and closing of the strip light source, and to perform crush detection on the acquired grain images.

[0021] The combing device consists of an F-shaped aluminum alloy frame and a brush, which is fixed to the combing plate by bolts to force comb the grains on the conveying device to avoid overlapping.

[0022] A multi-stage diversion method for detecting broken corn kernels, using a multi-stage diversion corn kernel breakage detection device as described above, includes the following steps:

[0023] S1. The feed servo motor and the discharge servo motor are controlled by the data acquisition and control device respectively, so that the feed port and the discharge port are in the open state.

[0024] S2. Control the conveying speed of the transmission device through the acquisition and control device, and control the strip light source to be in the on state;

[0025] S3. The collection device guides and controls the discharge of grains from the grain outlet, so that a fixed amount of grains are fed into the feed inlet.

[0026] S4. The grain sample is divided into multiple branches through the diversion channel of the first diversion plate and flows into the second diversion plate in sequence. The grain is then further diverted by the protruding columns on the second diversion plate, so that the grain is scattered on the conveying device in an approximately normal distribution.

[0027] S5. The conveying device transports the grains to the shooting range of the collection and control device, and under the forced brushing action of the brushing device, they form a single layer and an approximately normal distribution.

[0028] S6. The acquisition and control device captures images of the grain samples, performs image processing based on the deployed detection algorithm, completes the grain breakage detection, and outputs the grain breakage rate and the number of detected grains.

[0029] S7. The grain sample is conveyed to the discharge port by the conveying device and discharged to the outside of the device;

[0030] S8. Repeat steps S3 to S7 to complete the continuous measurement of grain sample breakage.

[0031] Compared with the prior art, the beneficial effects of the present invention are:

[0032] This invention, through the synergistic effect of a flow collection device and a multi-stage flow distribution mechanism, enables quantitative feeding and orderly flow of grain samples under high-throughput harvesting conditions. This allows the grains to form an approximately normal distribution during the material falling process. Combined with the forced brushing of the brushing device, the overlap and accumulation of grains are effectively eliminated, resulting in a single-layer uniform distribution of grains on the conveyor belt. This provides ideal sampling conditions for grain breakage detection, thereby improving the accuracy and reliability of the detection results.

[0033] This invention utilizes an integrated control scheme for the acquisition and control device to achieve synchronous control of the opening and closing of the inlet and outlet, the speed adjustment of the conveyor device, and the illumination of the light source. This effectively enables intermittent quantitative sampling of corn kernels and ensures consistent imaging conditions during image acquisition, reducing detection errors. Simultaneously, the acquisition and control device coordinates the movement of each component, improving the overall stability and automation level of the device. This invention features a compact structure and strong adaptability, making it stable for use in complex operating environments such as harvesters. It possesses excellent engineering practicality and broad prospects for widespread application. Attached Figure Description

[0034] To more clearly illustrate the technical solutions of the embodiments of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and detailed embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort, and all of them fall within the scope of protection of the present invention. Wherein:

[0035] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0036] Figure 2 This is a schematic diagram of the structure of the housing of the present invention;

[0037] Figure 3 This is a schematic diagram of the feed diversion function of the present invention;

[0038] Figure 4 This is a schematic diagram of the structure of the first flow divider of the present invention;

[0039] Figure 5 This is a schematic diagram of the structure of the second flow divider of the present invention.

[0040] The attached figures are labeled as follows:

[0041] 1. Shell; 101. Upper shell; 102. Lower shell; 103. Side wall shell; 104. Connecting plate; 105. Vibration damping pad; 106. Connecting vertical plate; 107. Comb horizontal plate; 108. Connecting horizontal plate; 2. Feeding device; 201. Feeding eye bolt; 202. Feeding plate; 203. Feeding servo device; 3. Diverting device; 301. First damping hinge; 302. First diverting plate; 303. Second damping hinge; 304. Second diverting plate; 4. Collecting device; 401. Collecting plate; 402. Inclined angle piece; 403. Rubber pad; 404. Drain plate; 5. Conveying device; 6. Acquisition and control device; 7. Discharge device; 701. Discharge eye bolt; 702. Discharge plate; 703. Discharge servo device; 8. Comb device; 9. Strip light source. Detailed Implementation

[0042] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0043] Please see Figures 1 to 5 An embodiment of the present invention provides a multi-stage diversion corn kernel crushing detection device, comprising a shell 1, a feeding device 2, a diversion device 3, a collecting device 4, a conveying device 5, a data acquisition and control device 6, a discharge device 7, a combing device 8, and a strip light source 9.

[0044] The housing 1 includes an upper housing 101, a lower housing 102, a side wall housing 103, a connecting plate 104, vibration damping pads 105, a connecting vertical plate 106, a comb horizontal plate 107, and a connecting horizontal plate 108. The upper housing 101 and the lower housing 102 are arranged opposite to each other, with an inlet and an outlet respectively. The connecting plate 104 has a U-shaped cross-section, and each end face is provided with a press-fit stud, which is installed at the connection between the upper housing 101 and the lower housing 102, and is fixed to the press-fit stud on the inner side of the end face by bolts to realize the connection between the upper housing 101 and the lower housing 102. The side wall housing 103 is installed on the upper housing 101. 01 is connected to both sides of the lower housing 102 and is fixed to the side of the connecting plate 104 by bolts and rivet studs. The vibration damping pad 105 is fixed to the outside of the lower housing 102 by bolts to absorb the vibration of operation and reduce the impact of mechanical vibration on the stability of image acquisition. The connecting vertical plate 106 has several slotted holes and is fixed to the inside of the upper housing 101 by L-shaped corner pieces. The comb horizontal plate 107 is fixed to the connecting vertical plate 106 by L-shaped corner pieces. The connecting horizontal plate 108 is fixed to the slotted holes in the connecting vertical plate 106 by L-shaped corner pieces. The imaging height can be changed by adjusting the position of the L-shaped corner pieces.

[0045] The feeding device 2 is installed inside the upper housing and includes a feeding eye bolt 201, a feeding plate 202, and a feeding servo motor device 203. The feeding eye bolt 201 is installed on both sides of the feeding port through flange nuts. The feeding plate 202 has short shafts on both sides and is hinged to the feeding eye bolt 201. The feeding servo motor device 203 is fixed to the L-shaped corner piece on the feeding plate 202 through a servo motor connecting rod. The servo motor drives the feeding plate 202 to rotate, thereby opening and closing the feeding port and completing the intermittent quantitative feeding of the grain sample.

[0046] The diversion device 3 is disposed inside the housing 1 and is used for multi-stage diversion of corn kernel material. It includes a first damping hinge 301, a first diversion plate 302, a second damping hinge 303, and a second diversion plate 304. The first damping hinge 301 is bolted to the connecting vertical plate 106. The first diversion plate 302 has diversion blocks distributed along its width for primary diversion of the corn kernels. The diversion blocks first gather the kernels before releasing them, reducing the kernel flow velocity and preventing excessive flow. In the event of a collision and bounce, the angle of the first diverter plate 302 can be adjusted and fixed by the first damping hinge 301, and the second damping hinge 303 is installed on the inner side of the upper housing 101 by bolts; the second diverter plate 304 is provided with cylindrical protrusions (as Galton nails), and their arrangement is completely in accordance with the arrangement law of Galton nail plates, which is used to perform secondary diversion of the grains, so that the grains are approximately normally distributed during the material falling process. The angle of the second diverter plate 304 can also be adjusted and locked by the second damping hinge 303.

[0047] The collecting device 4 is installed on the housing 1 and is used to quantitatively guide the grains discharged from the outlet to the inlet. It includes a collecting plate 401, an inclined angle piece 402, a rubber foot pad 403, and a drain plate 404. The collecting plate 401 is bolted to the inclined angle piece 402 at a fixed angle to guide part of the grains from the outlet to the inlet. The inclined angle piece 402 is bolted to the rubber foot pad 403, which is bolted to the upper side of the upper housing 101 to absorb the energy transmitted to the detection device by the impact of the grains. The grain sample feeding amount can be adjusted by adjusting the installation position of the rubber foot pad 403. The drain plate 404 is bolted to the inclined angle piece 402 and is arranged in a mirror image with the collecting plate 401 to drain excess grain samples and prevent grain accumulation.

[0048] The conveying device 5 is installed inside the housing 1 and is used to convey the grains to the image acquisition area and to the discharge port.

[0049] The acquisition and control device 6 is an image acquisition development board with a camera, which is set inside the housing 1. It is used to control the angle of the feeding servo device 203 and the discharging servo device 703, the conveying speed of the conveying device 5 and the opening and closing of the strip light source 9, and to perform crush detection on the acquired grain images. The acquisition and control device 6 has an embedded crush detection algorithm to analyze and process the acquired images, output the grain crushing rate and the number of detected grains, and realize the automatic identification and statistics of the crushing state.

[0050] The discharge device 7 is located on the outside of the housing 1 and is used to open and close the discharge port. It includes a discharge lifting eye bolt 701, a discharge plate 702 and a discharge servo motor device 703. The discharge lifting eye bolt 701 is installed on both sides of the discharge port through flange nuts. The discharge plate 702 has short shafts on both sides and is hinged in the discharge lifting eye bolt 701. The discharge servo motor device 703 drives the connecting rod through the servo motor to realize the rotation of the discharge plate to complete the opening and closing of the discharge port.

[0051] The combing device 8 consists of an F-shaped aluminum alloy frame and a brush, and is located inside the housing 1. It is fixed to the combing plate 107 by bolts to force comb the seeds on the conveying device 5, effectively eliminating stacking and overlapping, so that the sample is distributed in a single layer in the shooting area, thereby improving the accuracy and stability of visual inspection.

[0052] A strip light source 9 is located inside the housing 1 to provide illumination for image acquisition.

[0053] Based on the above-mentioned device, the present invention provides a method for detecting corn kernel breakage through multi-stage diversion, comprising the following steps:

[0054] S1. The feeding servo motor 203 and the discharging servo motor 703 are controlled by the acquisition and control device 6 respectively, so that the feeding port and the discharging port are in the open state.

[0055] S2. The conveying speed of the conveying device 5 is controlled by the acquisition and control device 6, and the strip light source 9 is controlled to be in the on state.

[0056] S3. The collection device 4 guides and controls the discharge of grains from the grain outlet, so that a fixed amount of grains are fed into the feed inlet.

[0057] S4. The grain sample is divided into multiple branches through the diversion channel of the first diversion plate 302 and flows into the second diversion plate 304 in sequence. Then, it is further diverted by the protruding column on the second diversion plate 304, so that the grains are scattered on the conveying device 5 in an approximately normal distribution.

[0058] S5. The conveying device 5 transports the grains to the shooting range of the collection control device 6, and under the forced combing action of the combing device 8, they form a single layer and an approximately normal distribution.

[0059] S6. The acquisition and control device 6 captures images of the grain samples, performs image processing based on the deployed detection algorithm, completes the grain breakage detection, and outputs the grain breakage rate and the number of detected grains.

[0060] S7. The grain sample is conveyed to the discharge port by the conveying device 5 and discharged to the outside of the device.

[0061] S8. Repeat S3 to S7 to achieve continuous measurement of grain sample breakage.

[0062] The above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A multi-stage diversion corn kernel crushing detection device, characterized in that: It includes a housing, a feeding device, a diverting device, a collecting device, a conveying device, a data acquisition and control device, a discharging device, a combing device, and a strip light source; The feeding device is mounted on the housing and is used to open and close the feed inlet; The diversion device is located inside the housing and is used to divert corn kernels in multiple stages. The collection device is installed on the shell and is used to quantitatively guide the grains discharged from the grain outlet to the feed inlet; The conveying device is located inside the housing and is used to transport the grains to the image acquisition area and then to the discharge port. The acquisition and control device is located inside the housing and is used to control the opening and closing of the inlet / outlet, the opening and closing of the strip light source, the operation of the conveyor device, and the acquisition and processing of corn kernel images. The discharge device is located on the outside of the housing and is used to open and close the discharge port; The combing device is located inside the housing and is used to comb the grains on the conveying device to avoid overlapping. A strip light source is located inside the housing to provide illumination for image acquisition; The housing includes an upper housing, a lower housing, a side wall housing, a connecting plate, vibration damping pads, a connecting vertical plate, a combing horizontal plate, and a connecting horizontal plate. The upper housing and the lower housing are arranged opposite to each other, with an inlet and an outlet respectively. The connecting plate has a U-shaped cross-section and is provided with press-fit studs on each end face. The connecting plate is installed at the connection between the upper housing and the lower housing and is fixed to the inner press-fit studs by bolts to realize the connection between the upper housing and the lower housing. The side wall housing is installed on both sides of the upper housing and the lower housing and is fixed to the side press-fit studs of the connecting plate by bolts. The vibration damping pads are fixed to the outside of the lower housing by bolts. The connecting vertical plate has several slotted holes and is fixed to the inside of the upper housing by L-shaped corner fittings. The combing horizontal plate is fixed to the connecting vertical plate by L-shaped corner fittings, and the connecting horizontal plate is fixed to the slotted holes in the connecting vertical plate by L-shaped corner fittings. The feeding device includes a feeding eye bolt, a feeding plate, and a feeding servo motor. The feeding eye bolt is installed on both sides of the feeding port through flange nuts. The feeding plate has short shafts on both sides and is hinged to the feeding eye bolt. The feeding servo motor drives the connecting rod through the servo motor to realize the rotation of the feeding plate, so as to complete the opening and closing of the feeding port. The diversion device includes a first damping hinge, a first diversion plate, a second damping hinge, and a second diversion plate. The first damping hinge is bolted to the connecting vertical plate. The first diversion plate is hinged to the connecting vertical plate via the first damping hinge. The first diversion plate is provided with diversion blocks distributed along the width direction for primary diversion of corn kernels. Its tilt angle is adjusted by the first damping hinge. The second damping hinge is bolted to the inner side of the upper housing. The second diversion plate is hinged to the inner side of the upper housing via the second damping hinge. The second diversion plate is provided with cylindrical protrusions as Galton nails for further diversion of kernels. Its tilt angle is adjusted by the second damping hinge. The collecting device includes a collecting plate, an inclined corner piece, rubber feet, and a drain plate. The collecting plate is bolted to the inclined corner piece at a fixed angle to guide a portion of the grains from the grain outlet to the feed inlet. The inclined corner piece is bolted to the rubber feet, which are bolted to the upper side of the upper housing to absorb the energy transmitted to the detection device by the impact of the grains. The drain plate is bolted to the inclined corner piece and is arranged in a mirror image with the collecting plate to discharge excess grain samples from the detection device.

2. The multi-stage diversion corn kernel crushing detection device according to claim 1, characterized in that: The discharge device includes a discharge lifting eye bolt, a discharge plate, and a discharge servo motor. The discharge lifting eye bolt is installed on both sides of the discharge port through flange nuts. The discharge plate has short shafts on both sides and is hinged in the discharge lifting eye bolt. The discharge servo motor drives the connecting rod to rotate the discharge plate and complete the opening and closing of the discharge port.

3. The multi-stage diversion corn kernel breakage detection device according to claim 2, characterized in that: The acquisition and control device is an image acquisition development board with a camera, used to control the angles of the feeding servo motor and the discharging servo motor, the conveying speed of the conveying device, and the opening and closing of the strip light source, and to perform crush detection on the acquired grain images.

4. The multi-stage diversion corn kernel breakage detection device according to claim 3, characterized in that: The combing device consists of an F-shaped aluminum alloy frame and a brush, which is fixed to the combing plate by bolts to force comb the grains on the conveying device to avoid overlapping.

5. A method for detecting corn kernel breakage using a multi-stage diversion system, employing the multi-stage diversion corn kernel breakage detection device according to any one of claims 1 to 4, characterized in that: Includes the following steps: S1. The feed servo motor and the discharge servo motor are controlled by the data acquisition and control device respectively, so that the feed port and the discharge port are in the open state. S2. Control the conveying speed of the transmission device through the acquisition and control device, and control the strip light source to be in the on state; S3. The collection device guides and controls the discharge of grains from the grain outlet, so that a fixed amount of grains are fed into the feed inlet. S4. The grain sample is divided into multiple branches through the diversion channel of the first diversion plate and flows into the second diversion plate in sequence. The grain is then further diverted by the protruding columns on the second diversion plate, so that the grain is scattered on the conveying device in an approximately normal distribution. S5. The conveying device transports the grains to the shooting range of the collection and control device, and under the forced brushing action of the brushing device, they form a single layer and an approximately normal distribution. S6. The acquisition and control device captures images of the grain samples, performs image processing based on the deployed detection algorithm, completes the grain breakage detection, and outputs the grain breakage rate and the number of detected grains. S7. The grain sample is conveyed to the discharge port by the conveying device and discharged to the outside of the device; S8. Repeat steps S3 to S7 to complete the continuous measurement of grain sample breakage.

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