A method, system, and storage medium for multi-directional positioning detection of a conveyor line.

Abstract

This invention discloses a multi-directional arrival detection method, system, and storage medium for a conveyor line. It involves arranging a first object detection sensor and a second object detection sensor diagonally in the transverse and longitudinal transport intersection areas of a pallet conveyor line. The method sets the position information of virtual deceleration detection points and virtual arrival detection points in each direction, as well as the conveyor line's operating parameters. It records the start and end time difference when one of the object detection sensors is blocked by the pallet. Combined with real-time readings of the actual conveyor line speed, it calculates the pallet's dimensions in the operating direction and synchronizes the actual conveyor line speed. It monitors in real-time the timing of the two sensors being triggered by the pallet; the first trigger is the deceleration point, and the second trigger is the arrival point. The distances from the two points to the corresponding virtual detection points are read according to the pallet direction. Combined with the conveyor line's rated high-speed and rated low-speed speeds, it calculates deceleration and arrival parameters. A deceleration command is sent upon reaching the deceleration time, and a stop command is sent upon reaching the arrival time. By using virtual detection points instead of physical sensors for positioning, the hardware cost of the sensors is reduced.

Description

Technical Field

[0001] This invention relates to the field of conveyor line control, and more particularly to a method, system, and storage medium for detecting multi-directional positioning of a conveyor line. Background Technology

[0002] Currently, the warehousing and logistics sector is rapidly developing towards automation and intelligence. As the core equipment for material flow, the conveyor line's arrival detection function is crucial for ensuring smooth material operation and precise stopping, directly impacting enterprise production efficiency and operating cost control. For the arrival detection requirements of multi-directional material feeding in conveyor lines, existing technologies generally employ a dual-sensor solution in one direction, as shown in the attached diagram. Figure 2 As shown, each feeding direction requires the installation of corresponding deceleration and positioning sensors. Taking four-way feeding as an example, eight physical sensors are needed: east-facing deceleration / positioning sensors, south-facing deceleration / positioning sensors, west-facing deceleration / positioning sensors, and north-facing deceleration / positioning sensors. Trigger signals from these dedicated sensors in each direction control the deceleration and stopping of the material in that direction. However, this existing technology not only has high hardware costs, but the number of sensors also increases exponentially with the feeding direction, further increasing equipment manufacturing costs. Furthermore, installation and debugging are difficult; each sensor needs precise positioning, and any positional deviation requires reinstallation, which is time-consuming and labor-intensive. Summary of the Invention

[0003] This invention addresses the shortcomings of existing technologies by providing a multi-directional positioning detection method for pallet conveyors. The pallet conveyor has a first object detection sensor and a second object detection sensor arranged diagonally along the intersection of its transverse and longitudinal conveying areas. The multi-directional positioning detection method specifically includes the following steps:

[0004] The location information of virtual deceleration detection points and virtual arrival detection points corresponding to the running direction of each pallet in the detection area, as well as the operating parameter information of the conveyor line, are set.

[0005] When the pallet enters the detection area from the front conveyor line, the starting time when one of the object detection sensors is blocked by the pallet and the ending time when the pallet leaves the sensor are recorded, and the time difference between the two times is calculated. Combined with the real-time reading of the actual speed of the conveyor line, the size of the pallet in the running direction is calculated. At the same time, the real-time reading and synchronization of the actual speed of the conveyor line are performed at a fixed period.

[0006] The system monitors the timing of the two arrival detection sensors triggered by the pallet in real time, compares the order of the two triggering times, and marks the sensor that was triggered first as the deceleration point and the sensor that was triggered later as the arrival point. Based on the current running direction of the pallet, the distance from the deceleration point to the virtual deceleration detection point and the distance from the arrival point to the virtual arrival detection point are read. The deceleration parameters and arrival parameters are calculated by combining the rated high speed and rated low speed of the conveyor line, respectively. When the time corresponding to the deceleration parameter is reached, a speed reduction command is sent to the drive device, and a stop command is sent when the time corresponding to the arrival parameter is reached. The speed reduction command is configured to control the conveyor line to reduce from the rated high speed to the rated low speed, and to ensure that the distance between the virtual deceleration detection point and the virtual arrival detection point meets the requirement of smooth speed reduction.

[0007] Preferably, the location information of the virtual deceleration detection points and virtual arrival detection points set in the detection area corresponding to the running direction of each pallet, as well as the operating parameter information of the conveyor line, include:

[0008] In the four pallet running directions of the detection area, four sets of virtual deceleration detection points and virtual arrival detection points are set with their corresponding position information. Each set of position information includes the minimum distance from the virtual deceleration detection point to the pallet boundary and the minimum distance from the virtual arrival detection point to the pallet boundary.

[0009] Obtain the current operating parameter information of the conveyor line, including the rated high speed and rated low speed of the conveyor line.

[0010] Preferably, the real-time monitoring of the two sensors being triggered by the tray designates the first trigger as the deceleration point and the second trigger as the arrival point. The distances from the two points to the corresponding virtual detection points are read according to the tray direction. Deceleration parameters and arrival parameters are calculated based on the rated high-speed and rated low-speed of the conveyor line. A deceleration command is sent upon reaching the deceleration time, and a stop command is sent upon reaching the arrival time. This includes:

[0011] The system monitors the timing of the two arrival detection sensors being triggered by the tray in real time, compares the order of the two triggering times, and marks the sensor that is triggered first as the deceleration point and the sensor that is triggered later as the arrival point.

[0012] Based on the current direction of travel, obtain the distance from the currently marked deceleration point to the corresponding virtual deceleration detection point. Calculate the deceleration trigger delay time ,in It is the rated high speed of the conveyor line; when the timer reaches the deceleration trigger delay time, a deceleration command is sent to the current conveyor line drive device. The deceleration command is configured to control the conveyor line to reduce from the rated high speed to the rated low speed, and to ensure that the distance between the virtual deceleration detection point and the virtual arrival detection point meets the requirements for smooth deceleration.

[0013] Get the distance from the currently marked arrival point to the corresponding virtual arrival detection point. Calculate the trigger delay time ,in It is the rated low speed of the conveyor line; when the timing reaches the trigger delay time, a stop command is sent to the current conveyor line drive device.

[0014] Preferably, the multi-directional positioning detection method for the conveyor line also includes:

[0015] During trayless calibration operation, if both the first and second object detection sensors output normal signals, the subsequent operation process will proceed. If one of the object detection sensors is found to be faulty, the signal of the faulty sensor will be blocked, the single sensor operation mode will be switched, and the corresponding emergency parameter calculation logic will be loaded. If both object detection sensors are faulty, an emergency stop command for the conveyor line will be issued.

[0016] Preferably, the single-sensor operation mode specifically includes:

[0017] If the second object detection sensor, which is the arrival point, fails, the deceleration trigger delay time is calculated based on the failure signal of the first object detection sensor. The distance from the currently marked deceleration point to the corresponding virtual deceleration detection point is obtained, and the substitute arrival trigger delay time is obtained based on the ratio of the fixed physical distance between the two arrival detection sensors in the running direction to the rated low speed of the conveyor line.

[0018] If the first object detection sensor, which serves as the deceleration point, fails, the replacement deceleration trigger delay time is determined by the ratio of the sum of the distance from the virtual deceleration detection point to the deceleration point and the distance from the end of the pallet to the first object detection sensor, to the rated high speed of the conveyor line. The replacement arrival trigger delay time is determined by the ratio of the fixed physical distance between the two arrival detection sensors in the running direction to the rated low speed of the conveyor line.

[0019] Preferably, the single-sensor operation mode specifically includes:

[0020] If the second object detection sensor, which is used as the deceleration point, malfunctions, then the fault signal of the first object detection sensor is used as a reference, and the distance from the currently marked deceleration point to the corresponding virtual deceleration detection point is obtained. Calculate the deceleration trigger delay time ,in It is the rated high speed of the conveyor line; calculate the delay time for the replacement to arrive. The signal loss due to a malfunction of the second object detection sensor is compensated by a preset distance L4 between the first object detection sensor and the end of the tray; wherein... This is the rated low speed of the conveyor line. , , L3 is the distance between the deceleration point and the arrival point in the running direction; L2 is the distance between the arrival point and the final stopping position of the pallet; L1 is the dimension of the pallet in the running direction. T1 is the real-time speed of the conveyor line, T2 is the total time the pallet runs on the conveyor line, T3 is the time from when the pallet is triggered to the point of stopping, and T4 is the time from when the timer starts from the point of deceleration triggered by the pallet to when the pallet is triggered to the point of stopping.

[0021] If the first object detection sensor, which serves as the deceleration point, fails, the backup deceleration trigger delay time is calculated based on the failure signal of the second object detection sensor. The signal loss due to a fault in the first object detection sensor is compensated by obtaining the distance L4 between the end of the tray and the first object detection sensor; at the same time, the delay time for the replacement to be triggered is calculated. .

[0022] This invention also discloses a multi-directional positioning detection system for a pallet conveyor line. At the intersection of the transverse and longitudinal conveying sections of the pallet conveyor line, a first object detection sensor and a second object detection sensor are respectively arranged diagonally along the intersection area. The multi-directional positioning detection system specifically includes:

[0023] The parameter setting module allows you to set the location information of the virtual deceleration detection points and virtual arrival detection points corresponding to the running direction of each pallet in the detection area, as well as the operating parameter information of the conveyor line.

[0024] Extract the size and speed module. When the pallet enters the detection area from the front conveyor line, record the start time when one of the object detection sensors is blocked by the pallet and the end time when the pallet leaves the sensor, and calculate the time difference between the two times. Combine the real-time reading of the actual speed of the conveyor line to calculate the size of the pallet in the running direction. At the same time, read and synchronize the actual speed of the conveyor line in real time at a fixed period.

[0025] The trigger command module monitors in real time the timing of the two arrival detection sensors being triggered by the tray, compares the order of the two trigger times, and marks the sensor that was triggered first as the deceleration point and the sensor that was triggered later as the arrival point. Based on the current running direction of the tray, it reads the distance from the deceleration point to the virtual deceleration detection point and the distance from the arrival point to the virtual arrival detection point. It calculates the deceleration parameters and arrival parameters in combination with the rated high speed and rated low speed of the conveyor line, respectively. When the time corresponding to the deceleration parameter is reached, it sends a speed reduction command to the drive device, and sends a stop command when the time corresponding to the arrival parameter is reached. The speed reduction command is configured to control the conveyor line to reduce from the rated high speed to the rated low speed, and to ensure that the distance between the virtual deceleration detection point and the virtual arrival detection point meets the requirement of smooth speed reduction.

[0026] Preferably, the parameter setting module includes:

[0027] In the four pallet running directions of the detection area, four sets of virtual deceleration detection points and virtual arrival detection points are set with their corresponding position information. Each set of position information includes the minimum distance from the virtual deceleration detection point to the pallet boundary and the minimum distance from the virtual arrival detection point to the pallet boundary.

[0028] Obtain the current operating parameter information of the conveyor line, including the rated high speed and rated low speed of the conveyor line.

[0029] The present invention also discloses a controller, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the steps of any of the methods described above.

[0030] The present invention also discloses a computer-readable storage medium storing a computer program that, when executed by a processor, implements the steps of any of the methods described above.

[0031] This embodiment discloses a multi-directional arrival detection method, system, and storage medium for a conveyor line. It involves arranging a first object detection sensor and a second object detection sensor diagonally in the transverse and longitudinal conveying intersection area of ​​the pallet conveyor line. Position information of virtual deceleration detection points and virtual arrival detection points in each direction, as well as the conveyor line's operating parameters, are set. The start and end time difference when one of the object detection sensors is blocked by the pallet is recorded. The pallet's dimensions in the running direction are calculated based on the real-time reading of the actual conveyor line speed, and the actual conveyor line speed is synchronized. The timing of the two sensors being triggered by the pallet is monitored in real time; the first trigger is the deceleration point, and the second trigger is the arrival point. The distance from the two points to the corresponding virtual detection points is read according to the pallet direction. Deceleration and arrival parameters are calculated based on the conveyor line's rated high-speed and rated low-speed speeds. A deceleration command is sent upon reaching the deceleration time, and a stop command is sent upon reaching the arrival time. Replacing physical sensors with virtual detection points for positioning reduces sensor hardware costs and solves the cumbersome installation and debugging problems of traditional methods. Real-time pallet size calculation also addresses the compatibility issues of traditional solutions that struggle to adapt to different pallet sizes.

[0032] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0033] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings:

[0034] Figure 1 This is a flowchart illustrating the multi-directional positioning detection method for the conveyor line disclosed in this embodiment.

[0035] Figure 2 This is a schematic diagram of the sensor arrangement for multi-directional positioning detection on an existing conveyor line.

[0036] Figure 3 This is a schematic diagram of the sensor arrangement for the multi-directional positioning detection method for the conveyor line disclosed in this embodiment.

[0037] Figure 4 This is a simplified schematic diagram illustrating a fault in the second object detection sensor at the location point, as disclosed in this embodiment.

[0038] Figure 5 This is a simplified schematic diagram of a faulty first object detection sensor, which serves as a deceleration point, as disclosed in this embodiment.

[0039] Figure 6 This is a schematic diagram of the multi-directional positioning detection system for the conveyor line disclosed in this embodiment. Detailed Implementation

[0040] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the described embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0041] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains. The terms “first,” “second,” and similar terms used in the specification and claims of this patent application do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, the terms “an” or “a” and similar terms do not indicate a limitation of quantity, but rather indicate the presence of at least one.

[0042] In this embodiment, as shown in the appendix Figure 1 As shown, a multi-directional positioning detection method for a pallet conveyor line is disclosed. At the intersection of the transverse and longitudinal conveying sections of the pallet conveyor line, a first object detection sensor and a second object detection sensor are respectively arranged diagonally along the intersection area. The multi-directional positioning detection method specifically includes the following steps:

[0043] Step S1: Set the position information of the virtual deceleration detection point and the virtual arrival detection point corresponding to the running direction of each pallet in the detection area, as well as the running parameter information of the conveyor line;

[0044] In this embodiment, step S1 specifically includes the following: setting the position information of four sets of virtual deceleration detection points and virtual arrival detection points in the four pallet running directions of the detection area. Each set of position information includes the minimum distance from the virtual deceleration detection point to the pallet boundary and the minimum distance from the virtual arrival detection point to the pallet boundary.

[0045] By setting virtual deceleration detection points and virtual arrival detection points in the four pallet running directions within the detection area, the position references for deceleration triggering and stop triggering are pre-planned for each running direction. This eliminates reliance on the physical installation positions of physical sensors in different directions, and eliminates the need to install physical deceleration and arrival sensors for each of the four running directions. This reduces the number of sensors used from the configuration source, directly lowering the hardware procurement and manufacturing costs of the conveyor line equipment. The minimum distance from the virtual deceleration and arrival detection points to the pallet boundary is clearly defined, binding the position judgment of the virtual detection points to the pallet's own boundary. This avoids position judgment deviations caused by differences in pallet specifications, ensuring that pallets of different sizes can be matched to the corresponding virtual detection points with a unified logic. Compared to traditional technologies that require precise positioning of physical sensors, parameterized setting of virtual detection points eliminates the need for on-site adjustment of the physical positions of physical sensors, significantly reducing the accuracy requirements and debugging difficulty of on-site installation, and shortening the deployment cycle of the conveyor line. The virtual detection point settings covering all four pallet running directions allow this detection method to directly adapt to the multi-directional running needs of pallets at the intersection of transverse and longitudinal conveyors, without requiring separate adjustments to the basic configuration for a single direction. This enhances the compatibility of the method with different conveying scenarios and reduces adjustment costs during subsequent scenario switching.

[0046] For details, see attached. Figure 3 As shown, the minimum distance from the virtual deceleration detection point to the pallet boundary in the perpendicular running direction is... The minimum distance from the virtual positioning detection point to the pallet boundary in the vertical running direction is The units are all in meters (M). The deceleration point is defined as the spatial position where the object detection sensor is triggered first when the material passes through the conveyor line; the arrival point is defined as the spatial position where the object detection sensor is triggered last when the material passes through the conveyor line. The two sensors do not distinguish between deceleration and arrival functions. When the material passes through the conveyor line, the first and second object detection sensors are triggered sequentially. The object detection sensor that is triggered first is defined as the deceleration point, and the object detection sensor that is triggered later is defined as the arrival point.

[0047] definition The dimension L represents the directional dimension of the pallet, expressed in meters (M). To improve production line compatibility, we need to accommodate pallets of different sizes. To obtain the length L value for different pallets, we calculate the pallet length using the trigger time of the object detection sensor on the upstream conveyor line. V is defined as the actual speed of the conveyor line, expressed in meters (M). The drive unit provides real-time feedback during operation. (Definition) The total time the pallet travels on the conveyor line, expressed in seconds (s), is the length of the pallet. The formula for calculating the pallet length is: .

[0048] definition The time from when the tray is triggered to the designated location to when it stops running, measured in seconds (s). Defines the distance between the point of contact and the final stopping position of the tray. The unit is M.

[0049]

[0050] definition The time, measured in seconds, is the time from the start of the deceleration point triggered by the pallet to the pallet's arrival point. The distance between the deceleration point and the arrival point in the running direction is defined. The unit is M.

[0051]

[0052] Define the distance between position detection 1 and the end of the tray. Unit: M.

[0053]

[0054] Obtain the current operating parameter information of the conveyor line, including the rated high speed and rated low speed of the conveyor line. The rated high speed of the conveyor line... Rated low speed of the conveyor line The units are all Obtaining the rated high-speed and rated low-speed of the conveyor line provides a core speed basis for subsequent calculations of the timing for switching from high speed to low speed and the timing for stopping from low speed to stop. This ensures that there are clear and consistent speed parameters to support the generation of deceleration and stop commands, avoiding the impact of inconsistent speed standards on control accuracy. A unified virtual detection point position benchmark and the rated speed parameters of the conveyor line allow for the calculation of deceleration and positioning parameters based on the same logic for pallets moving in different directions. This avoids inconsistencies in control standards due to different directions, laying the foundation for smooth deceleration and precise stopping of pallets in all directions.

[0055] Step S2: When the pallet enters the detection area from the front conveyor line, record the start time when one of the object detection sensors is blocked by the pallet and the end time when the pallet leaves the sensor, and calculate the time difference between the two times. Combine the actual speed of the conveyor line read in real time to calculate the size of the pallet in the running direction. At the same time, read and synchronize the actual speed of the conveyor line in real time at a fixed period.

[0056] By leveraging the process of a pallet obstructing a sensor when entering the detection area, the start and end times of obstruction are recorded and the time difference is calculated. Combined with real-time readings of the conveyor line's actual speed, the dimensions of the pallet in its running direction are calculated. This provides fundamental data support for detection control of pallets of different sizes, eliminating the need for additional dimensional measurement equipment. The actual conveyor line speed is continuously read and synchronized at fixed intervals to ensure that the speed data used in subsequent calculations of deceleration and positioning parameters is consistent with the real-time operating status of the conveyor line, preventing a decrease in control accuracy due to speed data lag or deviation. Pallet dimension calculation is performed using the object detection sensors already deployed in the detection system, eliminating the need for additional dedicated dimensional measurement hardware. This fully utilizes the functional value of existing sensors, simplifies system hardware configuration, and avoids unnecessary hardware investment.

[0057] By calculating the dimensions of different pallets in real time, the conveyor line can flexibly adapt to various pallet sizes without adjusting its hardware structure or replacing specialized detection components due to changes in pallet specifications. This significantly enhances its adaptability to diverse material conveying scenarios and reduces equipment adjustment costs associated with pallet size changes. Real-time synchronization of the conveyor line's actual speed ensures that subsequent speed-based deceleration trigger times and arrival trigger times accurately match the actual operating status of the conveyor line, avoiding problems such as deceleration timing deviations and stopping position offsets caused by inaccurate speed data. No additional pallet size measurement equipment is required; existing object detection sensors can be used for size calculation, reducing hardware procurement and installation costs. This also simplifies the system hardware structure, reduces debugging complexity caused by additional hardware, and shortens the overall deployment and debugging cycle of the conveyor line.

[0058] Step S3: Real-time monitoring of the timing when the two arrival detection sensors are triggered by the pallet. The order of the two trigger times is compared, with the sensor triggered first marked as the deceleration point and the sensor triggered later marked as the arrival point. The distances from the deceleration point to the virtual deceleration detection point and from the arrival point to the virtual arrival detection point are read based on the current running direction of the pallet. Deceleration parameters and arrival parameters are calculated by combining these with the rated high speed and rated low speed of the conveyor line, respectively. A deceleration command is sent to the drive device when the time corresponding to the deceleration parameter is reached, and a stop command is sent when the time corresponding to the arrival parameter is reached. The deceleration command is configured to control the conveyor line to reduce from the rated high speed to the rated low speed, while ensuring that the distance between the virtual deceleration detection point and the virtual arrival detection point meets the requirement for a smooth deceleration. Specifically, the definition... This represents the distance from the deceleration sensor to the virtual deceleration detection point, in meters (M). Definition The distance from the positioning sensor to the virtual positioning detection point is expressed in meters (M).

[0059] Define deceleration parameters The time from the deceleration sensor to the virtual deceleration detection point, in seconds. Define the positioning parameters. The time from the arrival sensor to the virtual arrival detection point, in seconds. Define the acceleration and deceleration of the conveyor line. The unit is Define the distance from the virtual deceleration point to the virtual deceleration point. ,Require >( ).

[0060] In this embodiment, step S3 specifically includes the following:

[0061] Step S31: Real-time monitoring of the trigger times of the two position detection sensors by the tray, comparing the order of the two trigger times, and marking the sensor that triggers first as the deceleration point and the sensor that triggers later as the arrival point. By real-time monitoring of the trigger times of the two position detection sensors by the tray and comparing the trigger order, the sensor that triggers first is marked as the deceleration point and the sensor that triggers later is marked as the arrival point. This eliminates the need to pre-set fixed deceleration or position functions for the sensors during the installation or design phase, breaking the fixed limitations of sensor functions and allowing the two sensors to flexibly adapt to multi-directional detection needs.

[0062] Step S32: Based on the current running direction, obtain the distance from the currently marked deceleration point to the corresponding virtual deceleration detection point. Calculate the deceleration trigger delay time ,in The speed is the rated high speed of the conveyor line. When the timing reaches the deceleration trigger delay time, a deceleration command is sent to the current conveyor line drive device. This deceleration command is configured to control the conveyor line to reduce from the rated high speed to the rated low speed, while ensuring that the distance between the virtual deceleration detection point and the virtual arrival detection point meets the requirement of smooth deceleration. Based on the current running direction of the pallet, the distances from the deceleration point to the virtual deceleration detection point and from the arrival point to the virtual arrival detection point are obtained. Combined with the rated high and low speeds of the conveyor line, the trigger delay times for deceleration and arrival are calculated respectively, so that the triggering timing of deceleration and stopping actions can accurately match the preset virtual detection point position, ensuring that the control logic is consistent with the virtual reference.

[0063] Step S33: Obtain the distance from the currently marked arrival point to the corresponding virtual arrival detection point. Calculate the trigger delay time ,in It is the rated low speed of the conveyor line; when the timing reaches the arrival trigger delay time, a stop command is sent to the current conveyor line drive device. When calculating the deceleration trigger delay time, it is simultaneously ensured that the distance between the virtual deceleration detection point and the virtual arrival detection point meets the requirements for smooth deceleration, so that there is no speed change during the process of the conveyor line decelerating from the rated high speed to the rated low speed; at the same time, the arrival trigger delay time controls the sending of the stop command, so that the pallet can accurately stop at the target position and avoid arrival deviation.

[0064] Using only two sensors, the system dynamically defines functions to cover multi-directional detection, eliminating the need for dedicated multi-directional sensors. This reduces the number of hardware components and lowers procurement costs. It also avoids the high-precision installation requirements associated with fixed sensor functions, simplifying debugging and shortening the conveyor deployment cycle. Smooth deceleration avoids the impact of sudden speed changes on pallets, materials, and equipment. By relying on virtual detection points and rated speed to calculate trigger timing, it ensures precise pallet docking and improves arrival detection accuracy. No additional hardware or structural adjustments are required. It adapts to multi-directional feeding based on trigger sequence judgment and parameter calculation, enhancing the method's versatility and scenario expansion capabilities.

[0065] In this embodiment, the multi-directional positioning detection method for the conveyor line further includes:

[0066] During trayless calibration operation, if both the first and second object detection sensors output normal signals, the subsequent operation process will proceed. If one of the object detection sensors is found to be faulty, the signal of the faulty sensor will be blocked, the single sensor operation mode will be switched, and the corresponding emergency parameter calculation logic will be loaded. If both object detection sensors are faulty, an emergency stop command for the conveyor line will be issued.

[0067] During the pallet-free calibration phase, by monitoring the signal output of the first and second object detection sensors, sensor malfunctions can be identified before formal pallet conveying operations. This prevents sensor faults from being hidden during actual operation, leading to pallet detection errors and abnormal control commands. Different handling methods are adopted for different sensor malfunctions: when a single sensor fails, the fault signal is shielded and the system switches to single-sensor operation mode, while loading corresponding emergency parameter calculation logic to ensure uninterrupted detection and control functions; when both sensors fail, an emergency stop command is immediately issued to prevent the conveyor line from blindly operating without detection, which could cause safety accidents or equipment damage. Loading corresponding emergency parameter calculation logic provides a suitable parameter calculation basis for single-sensor operation mode, allowing a single sensor to still meet the basic requirements of pallet deceleration and arrival detection when replacing dual sensors, avoiding detection loss of control due to missing parameters in emergency mode.

[0068] In this embodiment, the single-sensor operation mode specifically includes:

[0069] Step S101: If the second object detection sensor, which serves as the arrival point, fails, the deceleration trigger delay time is calculated based on the failure signal of the first object detection sensor. This is done by obtaining the distance from the currently marked deceleration point to the corresponding virtual deceleration detection point. A substitute arrival trigger delay time is then used, based on the ratio of the fixed physical distance between the two arrival detection sensors in the running direction to the rated low speed of the conveyor line. Calculation logic is constructed for different sensor failure scenarios. When the second object detection sensor, which serves as the arrival point, fails, the normal first object detection sensor is used as the reference. On one hand, the deceleration trigger delay time is calculated based on the distance between its associated deceleration point and the virtual deceleration detection point to ensure the deceleration function is not lost. On the other hand, the fixed physical distance between the two sensors in the running direction, combined with the rated low speed of the conveyor line, is used to supplement the arrival trigger delay time, filling the detection gap after the arrival point sensor failure.

[0070] In step S102, if the first object detection sensor, which serves as the deceleration point, fails, the replacement deceleration trigger delay time is calculated based on the ratio of the sum of the distance from the virtual deceleration detection point to the deceleration point and the distance from the end of the pallet to the first object detection sensor, to the rated high speed of the conveyor line. Similarly, the replacement arrival trigger delay time is calculated based on the ratio of the fixed physical distance between the two arrival detection sensors in the running direction to the rated low speed of the conveyor line. When the first object detection sensor, which serves as the deceleration point, fails, the replacement deceleration trigger delay time is calculated by integrating the distance from the virtual deceleration detection point to the deceleration point, the distance from the end of the pallet to the failed sensor, and the rated high speed of the conveyor line, ensuring that the deceleration timing calculation is not affected by the failure. At the same time, the replacement arrival trigger delay time is obtained based on the fixed physical distance between the two sensors and the rated low speed, maintaining the core function of arrival detection.

[0071] In this embodiment, the single-sensor operation mode specifically includes:

[0072] If the second object detection sensor, which is used as the deceleration point, malfunctions, then the fault signal of the first object detection sensor is used as a reference, and the distance from the currently marked deceleration point to the corresponding virtual deceleration detection point is obtained. Calculate the deceleration trigger delay time ,in It is the rated high speed of the conveyor line; calculate the delay time for the replacement to arrive. The signal loss due to a malfunction of the second object detection sensor is compensated by a preset distance L4 between the first object detection sensor and the end of the tray; wherein... This is the rated low speed of the conveyor line. , , L3 is the distance between the deceleration point and the arrival point in the running direction; L2 is the distance between the arrival point and the final stopping position of the pallet; L1 is the dimension of the pallet in the running direction. T1 is the real-time speed of the conveyor line, T2 is the total time the pallet runs on the conveyor line, T3 is the time from when the pallet is triggered to the point of stopping, and T4 is the time from when the timer starts from the point of deceleration triggered by the pallet to when the pallet is triggered to the point of stopping.

[0073] In this embodiment, the system has a fault-tolerant emergency operation mechanism. The object detection sensor outputs a signal when there is no pallet and the signal disappears when a pallet is present. If either the first or second object detection sensor malfunctions and fails to output a signal, the system triggers a fault alert based on a comparison of real-time task data and the real-time status of the arrival detection, facilitating timely handling by maintenance personnel. Specifically, the arrival period is defined as the period from when a pallet is detected to when the sensor stops sending signals. The non-arrival period is the period during which the sensor continues to send signals while the conveyor line between the two pallets operates at a high speed and uniform speed. The sum of the arrival period and the non-arrival period constitutes the working cycle.

[0074] If the system detects a signal loss during a non-positioning cycle, it indicates that at least one sensor has malfunctioned. A detection system is then introduced, including a detection method, a main control chip, and a signal processing module. The main control chip receives real-time task data from the signal processing module and the real-time status of the conveyor line. Based on the abnormal signal fed back by the processing module, it triggers a fault alert and issues an alarm. Then, based on the real-time task data and real-time status, it determines whether to activate the emergency mechanism and, according to the fault situation, calls the corresponding parameters to feed back to the detection method, allowing the conveyor line to determine the position information of the positioning task according to the fault-prone operating parameters.

[0075] If the interval between two cycles is too large under the same type of arrival task, it is suspected that there is a jam in the conveyor line, aging, or missing material pallets.

[0076] If the value remains too high over multiple work cycles, it is suspected that the conveyor line is experiencing a fault such as jamming or aging that causes deceleration. The system will trigger a fault reminder, issue an alarm, calculate new parameters based on the new cycle, and operate with the new parameters until manual intervention is required to complete the conveyor line repair.

[0077] If a specific cycle within multiple work cycles is significantly larger than expected, it is suspected that the corresponding tray is damaged. The system will trigger a fault alert, issue an alarm, mark the specific cycle, calculate new parameters for it, and run the specific cycle with the new parameters until manual intervention is required to repair or replace the tray.

[0078] For two intersecting conveyor lines, the working interval for conveying tasks is determined based on a trial run. When one conveyor line is performing its work cycle, the other is on standby. After the first conveyor line completes its task and a certain time delay has elapsed, the second conveyor line begins its task. This time delay is the working interval. If a fault occurs during the alternating conveying tasks of the two conveyor lines, causing a conflict between the two lines, the system will detect the parameters of the two conveyor lines. If the parameters deviate significantly from the settings, the system will suspend operation, trigger a fault alert, issue an alarm, and wait for manual intervention for repair before resuming operation.

[0079] If either the first or second object detection sensor malfunctions for a period of time, the system will activate an emergency mechanism and operate with the fault present. (See attached...) Figure 4 As shown, assuming the second object detection sensor at the arrival point malfunctions, the system automatically masks the malfunction signal and automatically adjusts the parameters. Specifically, the deceleration trigger delay time is: The arrival of a substitute triggers a delay: When the second object detection sensor, which serves as the arrival point, fails, the first object detection sensor, which is functioning normally, is used as a reference. On one hand, the deceleration trigger delay time is calculated based on the distance between the deceleration point associated with this sensor and the virtual deceleration detection point, ensuring that the deceleration control function is not interrupted. On the other hand, the backup arrival trigger delay time is calculated using the preset distance between the first object detection sensor and the end of the pallet, thereby compensating for the lack of arrival signal caused by the failure of the second object detection sensor. There is no need to stop the machine for maintenance due to the failure of a single sensor. By supplementing the calculation with parameters adapted to different failure scenarios, the conveyor line can still perform pallet deceleration, arrival detection and control normally in single-sensor mode, greatly reducing production stoppages caused by hardware failures, ensuring the continuity of the warehousing and logistics transportation process, and reducing efficiency losses and economic costs caused by downtime.

[0080] If the first object detection sensor, which serves as the deceleration point, fails, the backup deceleration trigger delay time is calculated based on the failure signal of the second object detection sensor. The signal loss due to a fault in the first object detection sensor is compensated by obtaining the distance L4 between the end of the tray and the first object detection sensor; at the same time, the delay time for the replacement to be triggered is calculated. .

[0081] As attached Figure 5 As shown, assuming the first object detection sensor, which serves as the deceleration point, malfunctions, the system automatically masks the fault signal from the first object detection sensor and automatically adjusts the parameters. Specifically, the replacement deceleration trigger delay time is as follows: The arrival of a substitute triggers a delay: When the first object detection sensor, which serves as the deceleration point, fails, the backup deceleration trigger delay time is calculated based on the normal second object detection sensor. This is achieved by integrating the distance from the virtual deceleration detection point to the deceleration point and the distance from the end of the pallet to the first object detection sensor, thus preventing the deceleration timing calculation from failing. Simultaneously, the backup arrival trigger delay time is also calculated using relevant distance data. This ensures that even if the deceleration point sensor fails, the deceleration and arrival trigger time calculations can still be completed normally. Parameters are supplemented using preset stable data such as the sensor-pallet distance and the fixed distance between sensors, preventing significant deviations in the trigger delay time calculation due to sensor failure. This ensures that even in emergency operation mode, the deceleration timing control and final stopping position of the pallet remain highly accurate, reducing material collisions and arrival deviations caused by emergency operation.

[0082] In another embodiment, if the pallet has deformities such as local bulges, dents, corner deformations, or edge wear such as burrs, gaps, or uneven surfaces, it will cause the sensor to generate a brief abnormal signal when it passes by. For example, a bulge on the pallet may briefly block the sensor, creating a short-term signal, or a gap may cause the sensor to briefly detect no obstruction, resulting in signal fluctuations. Such signals are caused by pallet defects and are generated by incomplete or abnormal pallets passing by. Their duration is much shorter than a valid signal, but they are easily misidentified and require additional filtering. Moreover, in actual working conditions, when there is material mixing or fluctuation in conveying speed, static preset parameters cannot adapt to dynamic conditions, and the errors in the virtual deceleration point and arrival point calculated from the preset fixed material length L and fixed running speed V increase. To solve the above problems, the following steps can be included.

[0083] Step S201: Read the basic data of the conveyor line and enter the preset parameters into the PLC parameter configuration module; define the timing characteristic parameters and build the timing characteristic library; collect the actual running data and statistically analyze the characteristic parameters and bind the direction labels; load the friction coefficient library and complete the storage of the basic parameters and timing characteristic library.

[0084] The system reads basic data such as the maximum operating speed of the conveyor line and the minimum material length to be detected. The preset parameters include the basic delay threshold, the uniform direction coefficient of the straight feeding direction, the heavy load judgment threshold, and the filter extension coefficient. These parameters are then entered into the parameter configuration module of the PLC control system. The timing feature library includes core timing feature parameters such as trigger sequence, occlusion duration ratio, and trigger time difference range. It collects operating data of materials of different sizes and masses in four straight directions, statistically analyzes the reasonable range of feature parameters in each direction, and binds corresponding direction labels. The friction coefficient library includes material type and conveyor surface status information, as well as preset safety distance, maximum deceleration, speed and position compensation gain. The system also completes the storage of basic parameters and feature libraries.

[0085] Specifically, first collect the maximum speed V of the conveyor line.max Minimum material length L min According to the formula Calculate the basic delay threshold T0 to filter interference. Since the material movement path is straight in all four directions, the angle between the material movement path and the diagonal of the sensor is consistent, and the signal duration is stable. A uniform preset direction coefficient K = 1.0~1.1 is used. Combined with the pressure sensor, a heavy load threshold and a 1.5 times filter extension coefficient are set. When the material mass exceeds this value, the system automatically triggers the filter extension mechanism. That is, the actual delay threshold T under heavy load is T = the original calculated value * 1.5, which adapts to the motion stability characteristics of heavy load materials. T0, K, and the heavy load threshold are entered into the PLC parameter module.

[0086] The triggering order O is defined as follows: O=1 indicates that sensor A triggers first, followed by sensor B; O=-1 indicates that sensor B triggers first, followed by sensor A. This serves as the basic feature for direction determination. The occlusion duration ratio R is calculated using the formula R=T. A / T B T A Let T be the duration of occlusion for sensor A. B The occlusion duration for sensor B is used to distinguish directions with the same triggering sequence but different paths. The triggering time difference range Δt records the reasonable interval of the triggering time difference between the two sensors under different directions, assisting in filtering abnormal signals.

[0087] Specifically, for all possible feed directions of the conveyor line, time-series characteristic data of typical materials are collected:

[0088] The selected sample materials cover representative materials of different sizes, such as 0.5m, 1m, and 2m, and different weights, such as light load 5kg and heavy load 50kg, to ensure that the samples cover common types in actual working conditions.

[0089] Material is conveyed in a directional manner through manual control or an automated program, allowing each type of material to pass through the conveyor line multiple times in a fixed direction, while simultaneously recording the trigger time and the start / end time of obstruction for sensors A and B.

[0090] Calculate feature values: For each data delivery, calculate the trigger sequence O, the occlusion duration ratio R, and the trigger time difference Δt, and record the corresponding material size and quality information to form the original dataset.

[0091] Based on the collected raw data, the characteristic parameter ranges for each direction are determined through statistical analysis: the dataset is grouped according to the feeding direction, and the average value and fluctuation range of the trigger sequence O and the occlusion duration ratio R are calculated for each group; the reasonable ranges of R value and Δt value for each direction are determined as the threshold of the feature library; each combination of characteristic parameters is bound to the corresponding feeding direction label to form a feature-direction mapping relationship. The determined characteristic parameters and mapping relationships are then entered into the system.

[0092] Specifically, a friction coefficient database is established to store friction coefficient data for different materials and conveying surfaces. Common material types on conveyor lines, such as cardboard boxes, plastic boxes, and metal boxes, and different conveying surface conditions, such as dry and slightly damp, are selected. The friction coefficient μ is measured experimentally. For example, a cardboard box is placed on a dry conveying surface, and the friction force F during uniform pulling is measured using a force gauge. Combined with the material mass m, the following calculations are performed:

[0093] μ = F / mg (g is the acceleration due to gravity);

[0094] Two-dimensional data tables are established according to material type and conveyor surface condition. For example, the coefficient of friction for cardboard boxes corresponds to μ=0.3 for dry conveyor surfaces and μ=0.25 for metal boxes for wet conveyor surfaces. This provides basic parameters for subsequent acceleration and inertial force calculations. Considering factors such as conveyor line wear and temperature changes, a fluctuation of ±5% is allowed for each set of friction coefficient values.

[0095] Define the system's safety thresholds and motion limits to ensure the stability of the control process: Set a safety distance, which is the preset distance between the material's position at the point where the primary sensor A stops blocking and the virtual deceleration point, based on the maximum speed V of the conveyor line. max and the shortest reaction time T of the material min Calculate the basic safety distance d0=V max *T min For materials longer than 1m, an additional 0.2m buffer distance is added, i.e., d = d0 + 0.2m; the maximum deceleration a is set based on motor performance and material stability requirements. max To prevent materials from tipping or sliding due to sudden braking; preset speed compensation gain K v and position compensation gain K p This is used to correct mechanical errors. For example, when a speed deviation Δv is detected, the actual speed is corrected as follows:

[0096] V=V0+K v *Δv, V0 is the actual running speed.

[0097] Step S202: Receive material quality data transmitted from the pressure sensor and obstruction information, trigger sequence, and pulse signal feedback from the object detection sensor; discard interference signals according to the basic delay threshold; call the timing feature library to verify signal validity, and combine the abnormal rules of non-arrival period signals to determine fault precursors and filter valid signals.

[0098] The system receives material mass m from the pressure sensor in real time, as well as signals such as material occlusion start / end time and trigger sequence from the object detection sensor, and simultaneously captures pulse signals from the object detection sensor. Based on the initial configuration of the basic delay threshold T0, interference signals with durations shorter than T0 are discarded, and the time period of valid signals is retained. The system calls the timing feature library to verify the validity of the captured signals. Simultaneously, it combines this with the aforementioned rule that the disappearance of non-position period signals indicates an anomaly to determine if there are any precursors to a fault. Finally, it filters out pure valid signals such as trigger sequence, occlusion duration, and time difference.

[0099] Specifically, the pressure sensor reads the material mass m in real time to obtain the material's physical properties; when the material passes through the conveyor line, the sensor is triggered to record timing signals such as the start / end time of the obstruction and the trigger sequence; the diagonal sensor A / B delay module discards signals whose duration is less than the basic delay threshold T and outputs valid signals.

[0100] Timing verification is performed based on a pre-defined timing feature library to determine signal validity, such as eliminating false triggers and interference signals. Signals that pass verification are then subjected to delay filtering to output stable feature signals, providing clean data for subsequent calculations.

[0101] Step S203: Calculate the real-time running speed of the material based on the effective signal and the physical distance between the sensor, and correct the deviation using speed compensation gain; generate virtual deceleration points and arrival point trigger times according to the occlusion end time and preset distance, and adjust the safety distance if the threshold is exceeded; calculate the inertial force by combining the material mass, acceleration, and friction coefficient, and obtain the speed and position compensation amount.

[0102] Based on the pre-processed valid signal, the real-time running speed of the material is calculated by combining the physical distance between the two sensors, and the speed deviation is corrected by using the preset speed compensation gain. According to the sensor occlusion end time, preset safety distance and arrival distance, the trigger time of the virtual deceleration point and the virtual arrival point are generated respectively. If the material length exceeds the preset threshold, the safety distance is automatically adjusted. In addition, the inertial force is calculated by combining the material mass, real-time acceleration and friction coefficient, and then the speed compensation amount and position compensation amount are obtained to ensure the accuracy of deceleration and arrival position.

[0103] Specifically, an infrared beam sensor with pulse output is selected, which can output two pulse signals for the start and end of occlusion. The duration of occlusion is accurately recorded by a timer. A Let T be the duration of occlusion of A. B The occlusion duration of B and the trigger time difference Δt=T B_start -T A_start T A_start Let T be the start time of occlusion of A. B_start Let Δt be the start time of B's ​​occlusion. When Δt is positive, A will trigger first; when Δt is negative, B will trigger first.

[0104] Taking the material moving from any direction, such as east to west, as an example, the key parameters are calculated through the following steps:

[0105] (1) The reverse running speed V, after the material front edge is blocked by A, it is blocked by B after a time of Δt, and the distance between the two sensors is L. ab Then the actual running speed V0=L ab / |Δt|. Velocity deviation detected and corrected: V = V0 + K v *Δv.

[0106] (2) Calculate the material length L. The length of the material in the running direction L = V * (T) A +T B ) / 2, take the average of the two to reduce the error.

[0107] (3) Dynamically generate virtual points. Taking the east-west direction as an example, generate virtual deceleration points and arrival points: The virtual deceleration point is based on the occlusion end time T of A. A_end Based on the reverse velocity V and the preset safety distance d, the trigger time is t=T. A_end +d / V. Virtual to-site occlusion end time T based on B. B_end Combined with the preset positioning distance D, which is the straight-line distance from the sensor triggered by sensor B to the final target stopping position of the material, the triggering time is t=T. B_end +D / V. If the material length L is greater than a preset threshold, d is automatically extended to avoid untimely deceleration of long materials. The system achieves accurate four-directional recognition by calculating O and R in real time and matching directional labels in the feature library.

[0108] Taking into account factors such as speed, inertia, and friction coefficient, the calculated speed compensation is used to correct speed deviations, and the position compensation is used to offset position errors caused by inertia and friction, ensuring the accuracy of deceleration and positioning.

[0109] When the conveyor speed changes, the material will slide or deviate due to inertia. The inertial force is:

[0110] 'a' is the acceleration of the conveyor line.

[0111] Inertia-induced velocity increments that need to be compensated:

[0112] , t delay This refers to the system response delay time.

[0113] Position compensation—predicting inertial slip distance and braking in advance:

[0114] Step S204: Send the deceleration and arrival trigger time to the motor control module to drive the motor to execute the deceleration and stopping procedure; monitor sensor signals and motor operating status and shield fault sensor signals, and adjust the trigger time according to preset emergency parameters.

[0115] Specifically, the dynamically calculated deceleration trigger time and arrival trigger time are sent to the motor control module, driving the motor to start the deceleration program according to preset logic. After reaching the virtual deceleration point, the operating status is adjusted, and the material is precisely stopped according to the arrival trigger time to ensure that the final stopping position meets the arrival accuracy requirements. At the same time, the sensor signals and motor operating status are monitored in real time. If a single sensor failure is detected, the faulty sensor signal is automatically blocked, and the deceleration trigger time and arrival trigger time are adjusted according to preset emergency parameters. If the fluctuation of sensor obstruction time exceeds the set value multiple times in a row, the automatic cleaning device command is triggered. In addition, the system continuously monitors data such as friction coefficient deviation, compensation amount abnormality, and arrival task cycle deviation. When problems such as conveyor line jamming, aging, or material tray damage are found, a fault reminder is triggered and temporary operating parameters are generated to achieve closed-loop management of equipment operation.

[0116] In another embodiment, as shown in the appendix Figure 6 As shown, a multi-directional arrival detection system for a conveyor line is also disclosed, including a parameter setting module 1, a size and speed extraction module 2, and a trigger command module 3. The parameter setting module 1 is used to set the position information of virtual deceleration detection points and virtual arrival detection points corresponding to the running direction of each pallet in the detection area, as well as the operating parameters of the conveyor line. The size and speed extraction module 2 is used to record the start time when one of the object detection sensors is blocked by the pallet and the end time when the pallet leaves the sensor when it enters the detection area from the front end of the conveyor line, and calculate the time difference between the two times. Combined with the real-time reading of the actual speed of the conveyor line, the size of the pallet in the running direction is calculated, and the actual speed of the conveyor line is read and synchronized in real time at a fixed period. Trigger command module 3 is used to monitor in real time the time when the two arrival detection sensors are triggered by the tray, compare the order of the two trigger times and mark the sensor that was triggered first as the deceleration point and the sensor that was triggered later as the arrival point. According to the current running direction of the tray, the distance from the deceleration point to the virtual deceleration detection point and the distance from the arrival point to the virtual arrival detection point are read. The deceleration parameters and arrival parameters are calculated by combining the rated high speed and rated low speed of the conveyor line, respectively. When the time corresponding to the deceleration parameter is reached, a speed reduction command is sent to the drive device, and a stop command is sent when the time corresponding to the arrival parameter is reached. The speed reduction command is configured to control the conveyor line to reduce from the rated high speed to the rated low speed, and to meet the requirement that the distance from the virtual deceleration detection point to the virtual arrival detection point meets the requirement of smooth speed reduction.

[0117] In this embodiment, the parameter setting module 1 includes: setting the position information of four sets of virtual deceleration detection points and virtual arrival detection points in the four pallet running directions of the detection area, respectively. Each set of position information includes the minimum distance from the virtual deceleration detection point to the pallet boundary and the minimum distance from the virtual arrival detection point to the pallet boundary; and obtaining the current operating parameter information of the conveyor line, which includes the rated high speed and rated low speed of the conveyor line.

[0118] It should be noted that the various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. Regarding the multi-directional positioning detection system for conveyor lines disclosed in the embodiments, since it corresponds to the multi-directional positioning detection method for conveyor lines disclosed in the embodiments, the description is relatively simple, and relevant parts can be referred to the method section.

[0119] In other embodiments, a controller is also provided, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the various steps of the multi-directional positioning detection method for the conveyor line as described in the above embodiments.

[0120] If the aforementioned multi-directional positioning detection system for conveyor lines is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the above-described embodiments of the present invention can also be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various embodiments of the multi-directional positioning detection method for conveyor lines described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable medium can include: any entity or device capable of carrying the computer program code, a recording medium, a USB flash drive, a portable hard drive, a magnetic disk, an optical disk, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium, etc. It should be noted that the content contained in the computer-readable medium may be appropriately added to or subtracted from the content as required by the legislation and patent practice in the jurisdiction. For example, in some jurisdictions, according to legislation and patent practice, the computer-readable medium may not include electrical carrier signals and telecommunication signals.

[0121] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

[0122] In summary, the above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made within the scope of the claims of the present invention should be covered by the present invention.

Claims

1. A multi-directional in-place detection method for a conveying line, for a pallet conveying line, characterized by, At the intersection of the transverse and longitudinal conveying of the pallet conveyor line, a first object detection sensor and a second object detection sensor are respectively arranged diagonally along the intersection area. The multi-directional positioning detection method of the conveyor line specifically includes the following steps: S1, set the position information of virtual deceleration detection points and virtual arrival detection points corresponding to each pallet running direction in the detection area, as well as the operating parameter information of the conveyor line; set the position information of four sets of virtual deceleration detection points and virtual arrival detection points for the four pallet running directions in the detection area, each set of position information including the minimum distance from the virtual deceleration detection point to the pallet boundary and the minimum distance from the virtual arrival detection point to the pallet boundary; obtain the current operating parameter information of the conveyor line, the operating parameter information including the rated high speed of the conveyor line and the rated low speed of the conveyor line; S2, when the pallet enters the detection area from the front conveyor line, record the start time when one of the object detection sensors is blocked by the pallet and the end time when the pallet leaves the sensor, and calculate the time difference between the two times. Combine the real-time reading of the actual speed of the conveyor line to calculate the size of the pallet in the running direction. At the same time, read and synchronize the actual speed of the conveyor line in real time at a fixed period. S3, monitor in real time the moment when the two object detection sensors are triggered by the tray, compare the order of the two triggering moments and mark the sensor that was triggered first as the deceleration point and the sensor that was triggered later as the arrival point. Read the distance from the deceleration point to the virtual deceleration detection point and the distance from the arrival point to the virtual arrival detection point according to the current running direction of the tray. Calculate the deceleration parameters and arrival parameters by combining them with the rated high speed and rated low speed of the conveyor line. Send a deceleration command to the drive device when the time corresponding to the deceleration parameter is reached, and send a stop command when the time corresponding to the arrival parameter is reached. The deceleration command is configured to control the conveyor line to decelerate from the rated high speed to the rated low speed, and to ensure that the distance from the virtual deceleration detection point to the virtual arrival detection point meets the requirement of smooth deceleration. S31, monitor in real time when the two object detection sensors are triggered by the tray, compare the order of the two triggering times and mark the sensor that is triggered first as the deceleration point and the sensor that is triggered later as the arrival point; S32, according to the current running direction, obtaining the distance from the deceleration point of the current mark to the corresponding virtual deceleration detection point , calculating a deceleration trigger delay time , wherein is the rated high-speed speed of the conveying line; when the timing reaches the deceleration trigger delay time, a speed-down instruction is sent to the current conveying line driving device, and the speed-down instruction is configured to control the conveying line to decrease from the rated high-speed to the rated low-speed, and the distance from the virtual deceleration detection point to the virtual arrival detection point meets the smooth deceleration requirement. S33, Obtain the distance from the currently marked arrival point to the corresponding virtual arrival detection point. Calculate the trigger delay time ,in It is the rated low speed of the conveyor line; when the timing reaches the trigger delay time, a stop command is sent to the current conveyor line drive device.

2. The multi-directional positioning detection method for a conveyor line according to claim 1, characterized in that, Also includes: During trayless calibration operation, if both the first and second object detection sensors output normal signals, the subsequent operation process will proceed. If one of the object detection sensors is found to be faulty, the signal of the faulty sensor will be blocked, the single sensor operation mode will be switched, and the corresponding emergency parameter calculation logic will be loaded. If both object detection sensors are faulty, an emergency stop command for the conveyor line will be issued.

3. The multi-directional positioning detection method for a conveyor line according to claim 2, characterized in that, The single-sensor operation mode specifically includes: S101, if the second object detection sensor at the arrival point fails, the first object detection sensor failure signal is used as a reference. The deceleration trigger delay time is calculated by obtaining the distance from the currently marked deceleration point to the corresponding virtual deceleration detection point. The replacement arrival trigger delay time is obtained by using the ratio of the fixed physical distance between the two object detection sensors in the running direction to the rated low speed of the conveyor line. S102, if the first object detection sensor, which is the deceleration point, fails, the ratio of the sum of the distance from the virtual deceleration detection point to the deceleration point and the distance from the end of the pallet to the first object detection sensor, to the rated high speed of the conveyor line, is used as the substitute deceleration trigger delay time; and the ratio of the fixed physical distance between the two object detection sensors in the running direction to the rated low speed of the conveyor line is used as the substitute arrival trigger delay time.

4. The multi-directional positioning detection method for a conveyor line according to claim 3, characterized in that, The single-sensor operation mode specifically includes: If the second object detection sensor, which is used as the deceleration point, malfunctions, then the fault signal of the first object detection sensor is used as a reference, and the distance from the currently marked deceleration point to the corresponding virtual deceleration detection point is obtained. Calculate the deceleration trigger delay time ,in It is the rated high speed of the conveyor line; calculate the delay time for the replacement to arrive. The distance between the preset first object detection sensor and the end of the tray is determined. To compensate for signal loss due to a malfunction in the second object detection sensor; among which This is the rated low speed of the conveyor line. L3 is the distance between the deceleration point and the arrival point in the running direction; L2 is the distance between the arrival point and the final stopping position of the pallet; L1 is the pallet running direction dimension; V is the real-time speed of the conveyor line; T1 is the total time the pallet runs on the conveyor line; T2 is the time from the pallet triggering the arrival point to the stop running; T3 is the time from the start of the timing of the pallet triggering the deceleration point to the time of the pallet triggering the arrival point. If the first object detection sensor, which serves as the deceleration point, fails, the backup deceleration trigger delay time is calculated based on the failure signal of the second object detection sensor. The signal loss due to a fault in the first object detection sensor is compensated by obtaining the distance L4 between the end of the tray and the first object detection sensor; at the same time, the delay time for the replacement to arrive is calculated. .

5. A multi-directional positioning detection system for a conveyor line, used to implement the multi-directional positioning detection method for a conveyor line as described in any one of claims 1-4, characterized in that, At the intersection of the transverse and longitudinal conveying of the pallet conveyor line, a first object detection sensor and a second object detection sensor are respectively arranged diagonally along the intersection area. The multi-directional positioning detection system of the conveyor line specifically includes: The parameter setting module allows you to set the location information of the virtual deceleration detection points and virtual arrival detection points corresponding to the running direction of each pallet in the detection area, as well as the operating parameter information of the conveyor line. Extract the size and speed module. When the pallet enters the detection area from the front conveyor line, record the start time when one of the object detection sensors is blocked by the pallet and the end time when the pallet leaves the sensor, and calculate the time difference between the two times. Combine the real-time reading of the actual speed of the conveyor line to calculate the size of the pallet in the running direction. At the same time, read and synchronize the actual speed of the conveyor line in real time at a fixed period. The trigger command module monitors in real time the moments when the two object detection sensors are triggered by the tray. It compares the order of the two trigger moments and marks the sensor that was triggered first as the deceleration point and the sensor that was triggered later as the arrival point. Based on the current running direction of the tray, it reads the distance from the deceleration point to the virtual deceleration detection point and the distance from the arrival point to the virtual arrival detection point. It calculates the deceleration parameters and arrival parameters in combination with the rated high speed and rated low speed of the conveyor line, respectively. When the time corresponding to the deceleration parameter is reached, it sends a deceleration command to the drive device and sends a stop command when the time corresponding to the arrival parameter is reached. The deceleration command is configured to control the conveyor line to decelerate from the rated high speed to the rated low speed, and to ensure that the distance between the virtual deceleration detection point and the virtual arrival detection point meets the requirement of smooth deceleration.

6. The multi-directional positioning detection system for a conveyor line according to claim 5, characterized in that, The parameter setting module includes: In the four pallet running directions of the detection area, four sets of virtual deceleration detection points and virtual arrival detection points are set with their corresponding position information. Each set of position information includes the minimum distance from the virtual deceleration detection point to the pallet boundary and the minimum distance from the virtual arrival detection point to the pallet boundary. Obtain the current operating parameter information of the conveyor line, including the rated high speed and rated low speed of the conveyor line.

7. A controller comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that: When the processor executes the computer program, it implements the steps of the method as described in any one of claims 1-4.

8. A computer-readable storage medium storing a computer program, characterized in that: When the computer program is executed by a processor, it implements the steps of the method as described in any one of claims 1-4.

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