A Precision Welding Concrete Dispensing System with a Multimodal Two-Level Storage Architecture

Abstract

This invention provides a precise welding material dispensing system with a multimodal, two-level storage architecture. A first acquisition module collects image data of welding materials in the primary storage area, and a first processing module determines the target quantity of welding materials for dispensing based on this image. A second acquisition module collects image data of welding materials in the secondary storage area, and a second processing module performs a first-time quantity verification before dispensing. A weighing module collects the weight data of the welding materials, and a second-time verification module performs a second-time quantity verification. This ensures a high degree of accuracy in dispensing welding materials, improves the work efficiency of drying personnel and welders, and achieves cost reduction and efficiency improvement.

Description

Technical Field

[0001] This invention relates to the field of welding technology management, and in particular to a precision welding material dispensing system with a multimodal two-level material storage architecture. Background Technology

[0002] In modern welding operations, precise control of welding materials, such as welding wire, plays a crucial role in ensuring smooth production processes and effective cost control. Traditional welding wire storage and inventory methods have numerous drawbacks, such as open storage making them susceptible to moisture, mixed storage leading to retrieval errors, unclear inventory levels, and the potential for errors due to manual operation. Furthermore, they are slow to respond to diverse welding wire retrieval needs within a short timeframe. Therefore, there is an urgent need for a multi-modal detection welding wire precision dispensing system that integrates efficient storage, rapid retrieval, and accurate inventory functions. Summary of the Invention

[0003] Based on the above, the present invention provides a welding material precision dispensing system with a multimodal two-level material storage architecture, which aims to solve the technical problems of low welding material retrieval efficiency and easy error in the prior art.

[0004] A welding material precision dispensing system with a multimodal two-level material storage architecture includes:

[0005] The first acquisition module and the first-level storage silo store welding materials. The first acquisition module acquires image data of welding materials in the area of ​​the first-level storage silo.

[0006] The second acquisition module and the secondary storage silo: the secondary storage silo receives the welding materials falling from the primary storage silo; the second acquisition module acquires image data of the welding materials in the area of ​​the secondary storage silo.

[0007] The first processing module, connected to the first acquisition module, is used to identify and determine the target quantity of welding materials based on the image data of welding materials in the primary storage silo area and to control the material release.

[0008] The second processing module, connected to the second acquisition module, is used to perform the first check on the quantity of welding materials based on the image data of welding materials in the secondary storage silo area and to control the material release.

[0009] The weighing module has a pallet that receives the welding materials falling from the secondary storage silo. The weighing module collects the weight data of the welding materials, and the secondary verification module is used to perform a second verification of the quantity of welding materials.

[0010] Furthermore, both the primary and secondary storage silos include material receiving openings, welding material guide rails, and insert movement rails.

[0011] The welding material is blocked by a discharge port at the bottom of the track. The insert slide rail has inserts, and the welding material slides in from the receiving opening and passes through the track.

[0012] The receiving opening of the secondary storage silo is adapted to the discharge opening of the primary storage silo;

[0013] The first processing module includes:

[0014] The first image recognition unit is used to process the welding material image data of the primary storage silo area to identify the target quantity of welding materials and the target insertion position of the welding materials in the primary storage silo arranged from bottom to top by the track.

[0015] The first control unit, connected to the first image recognition unit, is used to control the movement of the insert movement slide rail of the primary storage bin to insert the insert into the target insertion position, and to open the sealing mechanism of the discharge port of the primary storage bin so that the target amount of welding material below the insert falls into the receiving opening of the secondary storage bin.

[0016] The second processing module includes:

[0017] The second image recognition unit is used to process the welding material image data of the secondary storage bin area to identify the total number of welding materials actually passing through the track in the secondary storage bin.

[0018] The second control unit, connected to the second image recognition unit, is used to control the opening of the sealing mechanism of the discharge port of the secondary storage silo when the actual total number of welding materials is verified to be the target quantity, so that the welding materials fall into the tray.

[0019] Furthermore, multiple primary storage bins are set up in parallel and store different types of welding materials;

[0020] The receiving opening at the top of the secondary storage silo is compatible with the discharge outlet at the bottom of all primary storage silos.

[0021] The first processing module is used to: determine the image data of the welding material in the corresponding primary storage bins according to the target type of welding material and the distribution of the primary storage bins, so as to determine the target quantity of welding material in the corresponding primary storage bins and perform material release control.

[0022] Furthermore, both the first image recognition unit and the second image recognition unit include:

[0023] The preprocessing subunit is used to preprocess the welding material image data to obtain a preprocessed image;

[0024] The edge detection subunit, connected to the preprocessing subunit, is used to identify the edge information of the welding material in the preprocessed image based on the edge detection algorithm.

[0025] The feature extraction subunit is connected to the edge detection subunit and is used to process the edge information of the welding material using a contour analysis algorithm to extract the contour feature data of the welding material.

[0026] The feature recognition subunit is connected to the feature extraction subunit.

[0027] The feature recognition subunit of the first image recognition unit is used to identify the target quantity of welding material and the target insertion position of the welding material in the track of the primary storage bin.

[0028] The feature recognition subunit of the second image recognition unit is used to identify the total number of welding materials actually passing through the track in the secondary storage bin.

[0029] Furthermore, in the first image recognition unit, the feature recognition subunit calculates the total target size based on the unit size of the welding material and the target quantity, and determines the target insertion position in the primary storage bin based on the total target size and contour feature data.

[0030] Furthermore, in the second image recognition unit, the contour feature data extracted by the feature extraction subunit includes the contour features of the welding material passing through the track and the actual total size of the welding material;

[0031] The feature recognition subunit calculates the total number of welding materials passing through the track based on the actual total size and unit size of the welding materials.

[0032] Furthermore, in the first image recognition unit, the feature recognition subunit performs connected region marking and statistics on the contour feature data of the welding material based on the connected region algorithm, so as to determine the target quantity of welding material and the target insertion position in the primary storage bin.

[0033] Furthermore, in the second image recognition unit, the feature recognition subunit performs connected region marking and statistics on the contour feature data of the welding material based on the connected region algorithm, so as to determine the total number of actual welding materials passing through the track.

[0034] Furthermore, the secondary verification module calculates the actual total number of welding materials on the pallet based on the welding material weight data and the unit weight of the welding materials, and compares the actual total number of welding materials on the pallet with the target quantity to achieve a second verification of the welding material quantity.

[0035] Furthermore, the system also includes: an outer shell, a primary storage silo, a secondary storage silo, and a weighing module housed within the outer shell;

[0036] The outer casing is equipped with a control panel, which is connected to the first processing module and is used for:

[0037] Record basic data on welding materials, data on the release of welding materials, and the inventory quantity of welding materials in each primary storage silo;

[0038] Basic data on welding materials includes the type of welding materials in the primary storage silo and the quantity of welding materials added.

[0039] Welding material feeding data includes the target type and target quantity of welding materials;

[0040] Generate welding material feeding instructions based on welding material feeding data;

[0041] The first processing module is used to: obtain the image data of the welding material in the corresponding primary storage bin area according to the welding material feeding instruction and the basic data of the welding material, identify and determine the target quantity of welding material and perform feeding control;

[0042] The control panel is also used to update the welding material inventory of the primary storage bin after the welding material is discharged from the primary storage bin.

[0043] The beneficial technical effects of this invention are as follows: By setting up a two-stage storage silo, the first-stage storage silo stores welding materials and uses image analysis technology to identify the target quantity of welding materials for dispensing. The second-stage storage silo receives the welding materials dispensed from the first-stage storage silo and uses image analysis technology to verify the quantity of welding materials. Then, the weighing module performs a second verification. Through multiple automatic verification mechanisms, the high accuracy of the output welding wire quantity is ensured, improving the work efficiency of drying personnel and welders, and achieving cost reduction and efficiency improvement. Attached Figure Description

[0044] Figure 1 This is a schematic diagram of a welding material precision dispensing system with a multimodal two-level material storage architecture according to the present invention.

[0045] Figure 2 This is a schematic diagram of the structure of each level of the storage bins in the welding material precision dispensing system with a multimodal two-level storage architecture according to the present invention;

[0046] Figure 3 This is a schematic diagram of the structure of a welding material precision dispensing system with a multimodal two-level material storage architecture according to the present invention;

[0047] Figure 4 This is a schematic diagram of the first processing module of a welding material precision dispensing system with a multimodal two-level material storage architecture according to the present invention.

[0048] Figure 5 This is a schematic diagram of the second processing module of a welding material precision dispensing system with a multimodal dual-level material storage architecture according to the present invention.

[0049] Figure 6 This is a schematic diagram of the first / second image recognition unit of the welding material precision dispensing system with a multimodal dual-level material storage architecture according to the present invention. Detailed Implementation

[0050] 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.

[0051] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0052] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but this is not intended to limit the scope of the invention.

[0053] See Figure 1 and Figure 3 This invention provides a welding material precision dispensing system with a multimodal two-level material storage architecture, comprising:

[0054] The first acquisition module 1 and the primary storage bin 2, the primary storage bin 2 stores welding materials, and the first acquisition module 1 acquires image data of welding materials in the area of ​​the primary storage bin 2;

[0055] The second acquisition module 3 and the secondary storage bin 4, the secondary storage bin 4 receive the welding materials falling from the primary storage bin 1, and the second acquisition module 3 acquires the image data of the welding materials in the area of ​​the secondary storage bin 2;

[0056] The first processing module 5 is connected to the first acquisition module 1 and is used to identify and determine the target quantity of welding materials based on the welding material image data of the primary storage silo 2 area and to perform material release control.

[0057] The second processing module 6 is connected to the second acquisition module 3 and is used to perform the first check on the quantity of welding materials and control the material release based on the welding material image data of the secondary storage bin 4 area.

[0058] The weighing module 7 and the secondary verification module 8 are included. The weighing module 7 has a tray that receives the welding materials falling from the secondary storage bin 4. The weighing module 7 collects the weight data of the welding materials, and the secondary verification module 8 is used to perform a second verification of the quantity of welding materials.

[0059] Specifically, the welding materials are welding rods or welding wires.

[0060] Specifically, the cross-section of the welding material is circular.

[0061] When the second processing module 6 detects a discrepancy between the actual total number of welding materials and the target number, it generates a first warning message.

[0062] When the secondary verification module 8 detects a discrepancy between the actual total number of welding materials and the target quantity, it generates a second warning message.

[0063] It also includes an early warning module 16, which is connected to the second processing module 6 and the secondary verification module 8, respectively, and is used to notify the user of the first early warning information or the second early warning information.

[0064] This invention employs a two-stage material storage system. The first-stage storage silo stores welding materials and uses image analysis technology to identify the target quantity of welding materials before dispensing them. The second-stage storage silo receives the welding materials dispensed from the first-stage silo and verifies the quantity using image analysis technology. Subsequently, a weighing module performs a second verification. Through this multi-stage automatic verification mechanism, the high accuracy of the output welding material quantity is ensured. Precise control over the quantity of welding materials dispensed avoids material waste and repetitive operations caused by quantity errors, effectively reducing costs. At the same time, it improves the efficiency and accuracy of welders in retrieving welding materials, ensuring the smooth progress of the welding operation process.

[0065] Furthermore, multiple primary storage bins 2 are set up in parallel and store different types of welding materials;

[0066] The receiving opening at the top of the secondary storage silo 4 is compatible with the discharge outlet at the bottom of all primary storage silos 2.

[0067] Each primary storage bin corresponds to a primary data acquisition module;

[0068] The first processing module 5 is used to: call the corresponding welding material image data of the primary storage bin 2 according to the target type of welding material, determine the target quantity of welding material in the primary storage bin 2 and perform material release control.

[0069] Specifically, the weighing module is a pressure sensor. This invention constructs a three-layer collaborative precision architecture, consisting of an upper-layer multi-welding wire storage unit, a middle-layer calibration storage unit, and a lower-layer high-precision pressure sensing and detection layer.

[0070] The upper-level multi-welding wire storage unit includes multiple large primary storage bins arranged in parallel. Each primary storage bin holds different types of welding materials, i.e., different kinds and models of welding materials. Each primary storage bin is designed to hold 500 welding materials, such as welding rods or welding wires, and strictly adheres to the principle of storing only one type of material, eliminating the risk of mixing different types of welding wires from the structural design source.

[0071] Each primary storage silo is an independent functional module, integrating core functions such as accurate counting and intelligent material discharging.

[0072] The receiving opening of the secondary storage silo 4 is adapted to the discharge port of the primary storage silo 2. In other words, the projection of the receiving opening of the secondary storage silo 4 on the horizontal plane covers the projection of the discharge ports of all primary storage silos 2 on the horizontal plane. This ensures that the welding material falling from each primary storage silo 2 can seamlessly connect into the secondary storage silo 4.

[0073] See Figure 2 , Figure 3 , Figure 4 and Figure 5Furthermore, the structures of the primary storage bin 2 and the secondary storage bin 4 both include a material receiving opening 21, a welding material passage track 22, and an insert movement slide rail 23;

[0074] The welding material is blocked by a sealing mechanism 24 at the discharge port at the bottom of the track 22. The insert slide rail 23 has inserts, and the welding material slides into the track 22 from the receiving opening.

[0075] The receiving opening of the secondary storage silo 4 is adapted to the discharge opening of the primary storage silo 2;

[0076] The first processing module 5 includes:

[0077] The first image recognition unit 51 is used to process the welding material image data of the primary storage bin 2 area to identify the target quantity of welding materials and the target insertion position of the welding materials in the primary storage bin 2 arranged from bottom to top by the track.

[0078] The first control unit 52 is connected to the first image recognition unit 51. It is used to control the movement of the insert movement slide rail of the first-level storage bin 2 to insert the insert into the target insertion position, and to open the sealing mechanism of the discharge port of the first-level storage bin 2 so that the target amount of welding material below the insert falls into the receiving opening of the second-level storage bin 4.

[0079] The second processing module 6 includes:

[0080] The second image recognition unit 61 is used to process the welding material image data of the secondary storage bin 4 area to identify the actual total number of welding materials passing through the track in the secondary storage bin 4.

[0081] The second control unit 62 is connected to the second image recognition unit 61. When the total number of actual welding materials is verified to be the target quantity, it controls the opening of the sealing mechanism of the discharge port of the secondary storage bin 4 so that the welding materials fall into the tray.

[0082] In one embodiment of the present invention, the second image recognition unit 61 also identifies the target insertion position of the insert. When the actual total number of welding materials matches the target quantity, the second control unit 62 controls the movement of the insert sliding rail of the secondary storage bin 4 to insert the insert into the target insertion position, and opens the sealing mechanism of the discharge port of the secondary storage bin 4 so that the target quantity of welding materials below the insert falls into the tray below. Except for the larger receiving opening of the secondary storage bin, the secondary storage bin adopts the same structure as the primary storage bin, and also has an insert design to ensure accurate dispensing of the target quantity of welding materials.

[0083] The receiving openings of the primary storage bin 2 and the secondary storage bin 4 both adopt a uniquely designed inclined damping sliding slide structure, which enables the welding wire to be arranged in a single vertical direction under gravity.

[0084] In addition, see Figure 2 and Figure 3 The system also includes an outer casing 10, with the primary storage bin 2, secondary storage bin 4, and weighing module 7 all housed within the outer casing 10. The pallet can be lifted out of the outer casing 10 so that the welder can remove the released welding material. The outer casing 10 includes an upper cover plate, with a material-adding lock 11 on the edge of the upper cover plate and a locking mechanism on the upper edge of the side plate of the outer casing 10. The lock is opened when welding material needs to be added to the primary storage bin.

[0085] Furthermore, the outer casing 10 is also provided with a control panel 12 connected to the first processing module. The control panel 12 is connected to the first acquisition module 1, the second acquisition module 3, the first processing module 5, the second processing module 6, the weighing module 7, and the secondary verification module 8.

[0086] Control panel 12 is used for:

[0087] Enter the basic data of the welding materials. The basic data of the welding materials includes the type of welding materials stored in each primary storage silo, the quantity of welding materials added to the primary storage silo, the diameter of the welding materials, and the unit weight of the welding materials.

[0088] Enter welding material feeding data and generate welding material feeding instructions based on the welding material feeding data. The welding material feeding data includes the target type and target quantity of welding material.

[0089] Update the welding material inventory quantity. Automatically update the welding material inventory quantity of the corresponding primary storage silo based on the quantity of welding materials released from the primary storage silo, and also update the welding material inventory quantity of the corresponding primary storage silo based on the manually entered quantity of welding materials added.

[0090] The control panel 12 is also used to generate a prompt message to add welding materials when the quantity of welding materials in the primary storage bin is lower than the preset quantity, so as to prompt the user to add welding materials.

[0091] The first acquisition module 1 acquires welding material image data at preset time intervals or according to welding material feeding instructions.

[0092] The second acquisition module 2 acquires welding material image data at preset time intervals, or starts acquiring welding material image data according to the welding material feeding instruction, or acquires welding material image data after the first processing module 5 controls the feeding to end.

[0093] The second processing module 6 is connected to the first processing module 5 and is used to receive the welding material image data from the second acquisition module 2 after the first processing module 5 controls the material discharge from the primary storage silo, and to process and verify it once.

[0094] The weighing module 7 collects welding material weight data at preset time intervals, or starts collecting welding material weight data according to the welding material feeding instruction, or starts collecting welding material image data after the second processing module 6 controls the feeding to end.

[0095] The secondary verification module 8 is connected to the second processing module 6 and is used to receive the welding material weight data from the weighing module 7 for secondary verification after the second processing module 6 controls the material to be discharged from the secondary storage silo.

[0096] The control panel 12 allows users to input the target type and quantity of welding materials to be distributed. This enables the first processing module 5 to determine the primary storage bin to be identified based on the target type of the welding materials, and to identify and distribute the target quantity of welding materials within that primary storage bin. The control panel 12 can also handle other data input, such as setting the type of welding materials stored in each primary storage bin, and inputting the diameter and unit weight of each type of welding material.

[0097] As an embodiment of the present invention, the control panel 12 is also used to input the quantity of welding materials in each primary storage bin. After the first processing module 5 controls the primary storage bins to issue a target quantity of welding materials, the control panel 12 subtracts the issued quantity of welding materials and updates the quantity of welding materials in the primary storage bins. The user can query the remaining quantity of welding materials in each primary storage bin through the control panel. When the quantity is insufficient, the user unlocks the refill lock 11, opens the top cover, and refills the primary storage bin. After refilling, the user updates the quantity of welding materials on the control panel.

[0098] Furthermore, casters 13 are provided at the bottom of the outer casing 10. At least four casters are provided to facilitate the movement of the device.

[0099] Furthermore, the bottom of the outer casing 10 is also equipped with casters 13 and a power supply 14, which provides power support for starting the system.

[0100] Furthermore, a fence 9 is formed around the inner wall of the side plate of the outer shell 10. The area enclosed by the fence 9 is between the discharge port of the two-stage storage bin 4 and the pallet on the weighing module 7, ensuring that the welding material falling from the two-stage storage bin falls into the pallet.

[0101] The outer casing design solves the problem of existing open storage of welding materials being susceptible to moisture.

[0102] When the system receives an instruction from the control panel to retrieve the target quantity and type of welding material, the first processing module will accurately locate the position of the target quantity of welding material based on the image data acquired by the first acquisition module. When the demand is X pieces of welding material, the system will control the movement of the insert slide rail and accurately insert the insert at the position of the Xth piece of welding material. A smart opening and closing sealing device is set below the insert. Once the insert is in place, the sealing device at the outlet will automatically open, and the welding material below the insert will automatically fall into the secondary storage bin.

[0103] After the secondary storage silo receives welding materials from the upper-level primary storage silo, it can use the second acquisition module and the second processing module to re-verify the quantity of welding materials. Only after confirming that the quantity is correct can the materials be transported to the next level. When the second control unit 62 detects a discrepancy between the actual total number of welding materials and the target quantity, it generates an early warning message, thereby achieving accurate distribution and refined management of the quantity of welding materials.

[0104] See Figure 6 Furthermore, both the first image recognition unit 51 and the second image recognition unit 61 include:

[0105] The preprocessing subunit 511 is used to preprocess the welding material image data to obtain a preprocessed image.

[0106] The edge detection subunit 512 is connected to the preprocessing subunit 511 and is used to identify the edge information of the welding material in the preprocessed image based on the edge detection algorithm.

[0107] The feature extraction subunit 513 is connected to the edge detection subunit 512 and is used to process the edge information of the welding material using a contour analysis algorithm to extract the contour feature data of the welding material.

[0108] Feature recognition subunit 514 is connected to feature extraction subunit 513;

[0109] The feature recognition subunit of the first image recognition unit 51 is used to identify the target quantity of welding material and the target insertion position of the welding material in the track of the primary storage bin.

[0110] The feature recognition subunit of the second image recognition unit 61 is used to identify the total number of welding materials actually passing through the track in the secondary storage bin.

[0111] The preprocessing of welding material image data includes:

[0112] Image enhancement: Enhancement processing is performed on the acquired welding material image data to improve image clarity and contrast, highlighting the characteristics of the welding material;

[0113] Denoising filtering: Gaussian filtering is used to remove noise from the image, reducing the impact of noise on subsequent feature extraction and recognition.

[0114] Binarization: The image after enhancement and filtering is binarized to convert it into a black and white image as a preprocessed image, which facilitates subsequent edge detection and quantity analysis of welding materials.

[0115] As one embodiment of the present invention, each primary storage bin corresponds to a first acquisition module. When the type of welding material to be issued matches the type of welding material stored in the primary storage bin, the first processing module obtains the welding material image data collected by the first acquisition module corresponding to the primary storage bin storing the target type of welding material, and processes the welding material image data.

[0116] In another embodiment of the present invention, when a first acquisition module corresponds to multiple primary storage bins, the preprocessing subunit 511 performs segmentation processing on the welding material image data acquired by the first acquisition module according to the distribution of the primary storage bins before performing preprocessing, and segments out the welding material image data corresponding to the primary storage bins storing the target type of welding material to be issued, and then performs preprocessing.

[0117] Specifically, the edge detection algorithm uses the Canny edge detection algorithm to detect the edge information of the welding material in the image and separate the welding material from the background.

[0118] Furthermore, in the first image recognition unit 51, the feature recognition subunit calculates the total target size based on the unit size of the welding material and the target quantity, and determines the target insertion position in the primary storage bin based on the total target size and contour feature data.

[0119] Specifically, the unit size of the welding material is the diameter of the welding material, and the target total size is the total length of the target quantity of welding materials arranged vertically.

[0120] Specifically, in a preferred embodiment of the present invention, the feature recognition subunit uses the YOLO algorithm to determine the target quantity of welding material and the target insertion position based on the total target size and contour feature data. The target insertion position isolates the target quantity of welding material from the remaining welding material.

[0121] Furthermore, in the second image recognition unit 52, the contour feature data extracted by the feature extraction subunit includes the contour features of the welding material passing through the track and the actual total size of the welding material;

[0122] The feature recognition subunit calculates the total number of welding materials passing through the track based on the actual total size and unit size of the welding materials.

[0123] Specifically, the unit size of the welding material is the diameter of the welding material, and the actual total size of the welding material is the total length of the welding material arranged in the track.

[0124] Furthermore, in the first image recognition unit 51, the feature recognition subunit performs connected region marking and statistics on the contour feature data of the welding material based on the connected region algorithm, so as to determine the target quantity of welding material and the target insertion position in the primary storage bin.

[0125] In another preferred embodiment of the present invention, a connected component analysis algorithm is used to mark and count connected components in the image to obtain the target quantity of welding material. Simultaneously, the position and size of each connected component are determined, and the target insertion position is determined based on the statistics. The target insertion position isolates the target quantity of welding material from the remaining welding materials. Based on the position information of the connected components, the position of the target quantity of welding material is located. When the system receives an instruction to retrieve the target quantity of welding material, it can accurately locate the position of the Xth welding wire and control the insert to automatically insert into the target insertion position, achieving precise material dispensing.

[0126] Furthermore, in the second image recognition unit 61, the feature recognition subunit marks and counts the connected regions of the contour feature data of the welding material based on the connected region algorithm, so as to determine the total number of actual welding materials passing through the track.

[0127] In another preferred embodiment of the present invention, in the second image recognition unit 61, the feature recognition subunit marks and counts the connected regions in the image based on the connected region analysis algorithm to obtain the actual total number of welding materials.

[0128] Furthermore, the secondary verification module 8 calculates the actual total number of welding materials on the pallet based on the welding material weight data and the unit weight of the welding materials, and compares the actual total number of welding materials on the pallet with the target quantity to achieve a second verification of the welding material quantity.

[0129] Specifically, the weighing module employs a high-precision pressure sensor. This sensor can accurately measure the weight of the welding materials placed on it. By pre-entering the unit weight of different types and models of welding materials into the system and combining it with the real-time measured weight data, the actual total number of welding materials currently on the pressure sensor is accurately calculated.

[0130] When the welding wire falls from the middle-level secondary storage bin onto the lower pallet, the weighing module performs a second verification process to confirm whether the actual total number of welding materials matches the user's initial target quantity. If the quantities match, the user can successfully retrieve the welding materials, completing the entire accurate distribution and retrieval process. The surface of the pallet that contacts the welding materials is made of smooth stainless steel.

[0131] Furthermore, the first acquisition module 1 includes at least one camera 1a facing the primary storage silo area;

[0132] The second acquisition module 3 includes at least one camera 1a facing the secondary storage silo area.

[0133] The first acquisition module 1 and the second acquisition module 3 also include a lighting component 1b, which provides uniform and stable light to ensure clear imaging of the welding materials. The camera acquires image data of the welding materials at certain time intervals or upon receiving an acquisition command. The camera uses a high-definition imaging device to achieve clear image acquisition of neatly arranged welding materials, thereby enabling accurate counting.

[0134] The specific application principle of this invention is as follows.

[0135] Step 1: Equipment Preparation, Welding Consumable Storage, and Command Input. Power on the multimodal welding consumable precision dispensing system. Before the system automatically initializes, the drying operator must strictly adhere to the single-category storage principle, placing the welding consumables into the corresponding primary storage bins of the upper-level large-capacity storage unit, filling each primary storage bin to its designed capacity, for example, 500 units. After storage, the welder inputs the required type and target quantity of welding consumables via the control panel, preparing for the subsequent retrieval process.

[0136] Step 2: Upper-layer material discharge and middle-layer verification. Within the upper-layer large-capacity storage unit, the primary storage silo corresponding to the required welding wire is activated. Using the first acquisition module, images are captured, and a counting algorithm locates the target quantity of welding material. Automatic inserts are then controlled, allowing the target quantity of welding material below the inserts to fall into the middle-layer transition storage unit. The middle layer uses the second acquisition module and the secondary storage silo to verify the quantity of welding material. Once confirmed, the material continues to be conveyed downwards.

[0137] Step 3: Lower-level verification and retrieval. The welding materials fall onto the tray of the lower-level high-precision weighing module. This layer measures the weight of the welding materials and calculates the quantity based on the unit weight, comparing it with the welder's initial target quantity. If the quantities match, the welder can retrieve the welding materials for actual welding operations.

[0138] This invention utilizes a photoelectric counting dual-storage bin and a weighing-type welding material counting device. It constructs a precise three-layer collaborative architecture: an upper-layer multi-welding wire storage bin unit, a middle-layer verification storage bin unit, and a lower-layer high-precision pressure sensing detection layer. This achieves refined classification and storage, accurate counting, automatic dispensing, and rapid retrieval of welding materials in three aspects. First, the upper layer has N parallel primary storage bins that, based on preset instructions, use optical signals and image recognition technology to accurately control the quantity and type of welding materials, efficiently dispensing the required materials through an automatic dispensing mechanism. Second, the middle-layer verification stage uses a "high-definition camera + counting algorithm" to perform an initial check on the dispensed welding materials. Third, the lower-layer high-precision weighing verification system accurately converts weight data into quantity information based on the density characteristics of different welding materials. Through this multi-layered verification mechanism, the high accuracy of the output welding material quantity is ensured.

[0139] The above are merely preferred embodiments of the present invention and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should recognize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present invention should be included within the protection scope of the present invention.

Claims

1. A welding material precision dispensing system with a multimodal two-level material storage architecture, characterized in that, include: A first acquisition module and a primary storage silo, wherein the primary storage silo stores welding materials, and the first acquisition module acquires image data of the welding materials in the area of ​​the primary storage silo; The second acquisition module and the secondary storage bin are used to collect welding materials that fall from the primary storage bin. The second acquisition module collects image data of the welding materials in the area of ​​the secondary storage bin. The first processing module, connected to the first acquisition module, is used to identify and determine the target quantity of welding materials based on the welding material image data of the primary storage silo area and to perform material release control. The second processing module, connected to the second acquisition module, is used to perform a first check on the quantity of welding materials based on the welding material image data of the secondary storage silo area and to control the material release. The weighing module includes a weighing module and a secondary verification module. The weighing module has a tray for receiving welding materials falling from the secondary storage silo. The weighing module collects the weight data of the welding materials, and the secondary verification module is used to perform a second verification of the quantity of welding materials. Both the primary storage silo and the secondary storage silo include a material receiving opening, a welding material passage rail, and a slide rail for insert movement. The welding material is sealed through the discharge port at the bottom of the track by a sealing mechanism. The insert slide rail is equipped with inserts. The welding material slides into the track from the receiving opening. The receiving opening of the secondary storage silo is adapted to the discharge opening of the primary storage silo; The first processing module includes: The first image recognition unit is used to process the welding material image data of the primary storage bin area to identify the target quantity of welding materials and the target insertion position of the welding materials in the primary storage bin arranged from bottom to top by the track; The first control unit, connected to the first image recognition unit, is used to control the movement of the insert movement slide rail of the first-level storage bin to insert the insert into the target insertion position, and to open the sealing mechanism of the discharge port of the first-level storage bin so that the target number of welding materials below the insert falls into the receiving opening of the second-level storage bin. The second processing module includes: The second image recognition unit is used to process the welding material image data of the secondary storage bin area to identify the total number of welding materials actually passing through the track in the secondary storage bin. The second control unit, connected to the second image recognition unit, is used to control the opening of the sealing mechanism of the discharge port of the secondary storage silo when the total number of actual welding materials is verified to be the target quantity, so that the welding materials fall into the tray.

2. The welding material precision dispensing system with a multimodal two-level material storage architecture as described in claim 1, characterized in that, Multiple primary storage bins are arranged in parallel and store different types of welding materials; The receiving opening at the upper end of the secondary storage silo is compatible with the discharge outlets at the lower end of all the primary storage silos. The first processing module is used to: determine the image data of the welding material in the corresponding primary storage bin according to the target type of welding material and the distribution of the primary storage bin, so as to determine the target quantity of welding material in the corresponding primary storage bin and perform material release control.

3. The welding material precision dispensing system with a multimodal two-level material storage architecture as described in claim 1, characterized in that, Both the first image recognition unit and the second image recognition unit include: The preprocessing subunit is used to preprocess the welding material image data to obtain a preprocessed image; An edge detection subunit, connected to the preprocessing subunit, is used to identify welding material edge information in the preprocessed image based on an edge detection algorithm; The feature extraction subunit, connected to the edge detection subunit, is used to process the edge information of the welding material using a contour analysis algorithm to extract the contour feature data of the welding material. A feature recognition subunit is connected to the feature extraction subunit; The feature recognition subunit of the first image recognition unit is used to identify the target quantity of welding material passing through the track and the target insertion position of the welding material in the primary storage bin; The feature recognition subunit of the second image recognition unit is used to identify the total number of welding materials actually passing through the track in the secondary storage bin.

4. The welding material precision dispensing system with a multimodal two-level material storage architecture as described in claim 3, characterized in that, In the first image recognition unit, the feature recognition subunit calculates the total target size based on the unit size of the welding material and the target quantity, and determines the target insertion position in the primary storage bin based on the total target size and the contour feature data.

5. The welding material precision dispensing system with a multimodal two-level material storage architecture as described in claim 3, characterized in that, In the second image recognition unit, the contour feature data extracted by the feature extraction subunit includes the contour features of the welding material in the track and the actual total size of the welding material; The feature recognition subunit calculates the total number of welding materials passing through the track based on the actual total size of the welding material and the unit size of the welding material.

6. The welding material precision dispensing system with a multimodal two-level material storage architecture as described in claim 3, characterized in that, In the first image recognition unit, the feature recognition subunit marks and counts the connected regions of the contour feature data of the welding material based on the connected component algorithm, so as to determine the target quantity of welding material and the target insertion position in the primary storage bin.

7. The welding material precision dispensing system with a multimodal two-level material storage architecture as described in claim 3, characterized in that, In the second image recognition unit, the feature recognition subunit marks and counts the connected regions of the contour feature data of the welding material based on the connected component algorithm, so as to determine the total number of actual welding materials passing through the track.

8. The welding material precision dispensing system with a multimodal two-level material storage architecture as described in claim 3, characterized in that, The secondary verification module calculates the actual total number of welding materials on the tray based on the welding material weight data and the unit weight of the welding materials, and compares the actual total number of welding materials on the tray with the target quantity to achieve a second verification of the welding material quantity.

9. The welding material precision dispensing system with a multimodal two-level material storage architecture as described in claim 2, characterized in that, The system also includes an outer shell, in which the primary storage bin, the secondary storage bin, and the weighing module are disposed; The outer casing is provided with a control panel, which is connected to the first processing module and is used for: Record basic data of welding materials, data on the release of welding materials, and the inventory quantity of welding materials in each of the primary storage bins; The basic data of the welding materials includes the type of welding materials in the primary storage silo and the quantity of welding materials added. The welding material feeding data includes the target type and target quantity of the welding material; A welding material feeding instruction is generated based on the welding material feeding data; The first processing module is used to: obtain the image data of the welding material in the corresponding primary storage bin area according to the welding material feeding instruction and the basic data of the welding material, identify and determine the target quantity of welding material and perform feeding control; The control panel is also used to update the welding material inventory quantity of the primary storage silo after the welding material is discharged from the primary storage silo.

Images