Full-automatic visual counting vertical packaging machine

Abstract

The invention relates to the technical field of packaging machinery, in particular to a full-automatic visual counting vertical packaging machine. The packaging machine comprises a supporting bottom frame, a supporting top frame, a hopper assembly, a vibration feeding mechanism, a quantitative material taking frame and a packaging mechanism. A plurality of metering cups are arranged at the bottom of the quantitative material taking frame, a material blocking plate is arranged on the supporting bottom frame, and a material blocking partition plate is arranged at a material discharging opening of the material blocking plate. Innovatively, a visual counting assembly is arranged on the front side of a supporting top frame, two counting cameras of the visual counting assembly are used for collecting images of full-load metering cups about to reach a discharging opening and empty metering cups completing discharging correspondingly, and the actual packaging number is accurately obtained by calculating the difference value of the material number of the full cups and the material number of the empty cups; the problem of inaccurate counting caused by material adhesion and wall hanging is effectively solved. According to the automatic packaging machine, rotating disc type quantitative material taking and dual-vision checking are combined, and high-speed and high-precision automatic packaging is achieved.

Description

Technical Field

[0001] This invention relates to the field of packaging machine technology, specifically to a fully automatic visual counting vertical packaging machine. Background Technology

[0002] Fully automatic vision-counting vertical packaging machines are key equipment in the modern packaging industry, widely used in food, pharmaceutical, hardware, and electronics industries for the accurate counting and automated packaging of regular materials. These machines typically include basic functional modules such as material storage, feeding, counting, and sealing. Their core objective is to maximize packaging efficiency while ensuring counting accuracy, to meet the demands of large-scale industrial production. In existing technologies, to achieve efficient continuous operation, buffer mechanisms are usually used to coordinate the cycle time differences between the counting and sealing processes, avoiding equipment downtime due to waiting times.

[0003] In existing technical solutions, such as the fully automatic visual counting vertical packaging machine disclosed in Chinese patent CN221914945U, a dual-buffer structure of a first hopper and a second hopper is used to connect the feeding channel and the packaging mechanism. The basic logic of this solution is: when the first hopper receives and buffers the material from the feeding channel, the second hopper can release its buffered material to the packaging process, thereby realizing parallel operation of feeding and packaging and reducing the idle time of the feeding channel. However, this design has several inherent defects. First, it relies on visual counting during the flow of material in the feeding channel, and the counting accuracy will decrease significantly for materials that are prone to overlapping or sticking. Second, its buffering and release mechanism mainly relies on the opening and closing of the baffle at the bottom of the hopper. This centralized unloading method is prone to causing blockage or damage to irregularly shaped or fragile materials. More importantly, the material flow path of this structure is long and involves many steps, making it difficult to avoid cumulative errors. Furthermore, the overall mechanical structure is poorly adaptable to material characteristics, making it difficult to ensure both high efficiency and high precision and reliability. This has become a bottleneck restricting its application in demanding packaging scenarios. Summary of the Invention

[0004] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a fully automatic visual counting vertical packaging machine, which solves the problems mentioned in the background section.

[0005] (II) Technical Solution To achieve the above objectives, the present invention is implemented through the following technical solution: a fully automatic visual counting vertical packaging machine, including a supporting base frame, a supporting top frame fixedly connected to the upper side wall of the supporting base frame, a hopper assembly fixedly connected to the upper side wall of the supporting top frame, four supporting springs provided on the supporting top frame, a vibrating frame installed at the upper end of the four supporting springs, and a guide plate installed at the output end of the vibrating frame; A quantitative feeding rack is installed on the top of the support base and in front of the support top frame. The bottom of the quantitative feeding rack is provided with several through holes. A measuring cup is fixedly connected to the bottom of each through hole. A baffle plate is fixedly connected to the upper side wall of the support base. A discharge port is provided inside the baffle plate. A baffle partition is slidably connected inside the discharge port. A support plate is fixedly connected to the front side wall of the support top frame. A visual counting component is installed on the upper side wall of the support plate, and two counting cameras are installed on the lower side wall of the support plate. The two counting cameras are located on both sides of the discharge port. A discharge hopper is installed directly below the discharge port. A discharge pipe is fixedly connected to the lower end of the discharge hopper. A transmission belt assembly is provided on both the left and right sides of the discharge pipe. A longitudinal sealing frame assembly is fixedly connected to the front side wall of the support base. A transverse sealing and cutting assembly is provided on the front side wall of the support base and directly below the longitudinal sealing frame assembly.

[0006] Preferably, a guide plate is fixedly connected inside the support base frame. The guide plate is located directly below the horizontal sealing and cutting assembly, and its surface is inclined or curved. It is used to receive and guide the cut packaging bags to reduce their falling speed and impact force, and achieve orderly collection. The surface of the guide plate is also covered with a layer of shock-absorbing and wear-resistant material.

[0007] Preferably, the vibratory feeding mechanism includes a vibratory frame mounted on a support top frame by four support springs. The vibratory frame consists of a vibratory motor and a transmission frame. A support base plate is installed on the lower side wall of the vibratory motor. The lower end of the support base plate cooperates with the support springs. The output end of the vibratory motor is fixedly connected to the bottom of the guide plate through the transmission frame to drive it to generate high-frequency micro-amplitude vibration. The guide plate is aligned with the discharge port of the hopper assembly. A discharge control valve for precisely controlling the material flow rate is installed inside the discharge port of the hopper assembly.

[0008] Preferably, the quantitative feeding rack rotates via a combination of a rotary motor and a reducer. The reducer is a precision planetary reducer to ensure the indexing accuracy and stopping accuracy of the quantitative feeding rack. The output end of the rotary motor is fixedly connected to the input end of the reducer, and the output end of the reducer is fixedly connected to the center of the lower side wall of the quantitative feeding rack. A sealing frame is installed on the upper side wall of the support base near the front. A material-blocking cylinder is installed on the upper side wall of the sealing frame. The output end of the material-blocking cylinder is fixedly connected to a material-blocking partition. A sealing strip is embedded at the bottom of the material-blocking partition to form a seal with the discharge port when closed, preventing material leakage.

[0009] Preferably, a drive motor is installed inside the support base frame, a transmission box is installed at the output end of the drive motor, a transmission housing is installed on the right side wall of the transmission housing, and two meshing transmission gears are arranged inside the transmission housing. The transmission gears are helical gears to improve transmission smoothness and torque. One of the transmission gears is fixedly connected to the output end of the transmission housing. A sliding universal joint is installed on the right side wall of each transmission gear. The transmission belt assembly consists of a driving synchronous pulley, a transmission belt body, and a driven synchronous pulley. The output end of the sliding universal joint is fixedly connected to the driving synchronous pulley to compensate for installation errors and transmit power.

[0010] Preferably, a connecting frame is installed on the rear sidewall of each of the transmission belt assemblies. The driving and driven synchronous pulleys are rotatably connected to the connecting frame. The driving and driven synchronous pulleys mesh with the transmission belt body. The inner side of the transmission belt body has double-sided teeth, and the outer side is a smooth plane, which are used for transmission and clamping of packaging film, respectively. Two sets of electric slide assemblies are installed on the front sidewall of the support base. Each set of electric slide assemblies has two output motors. Each output motor is fixedly connected to the connecting frame and is used to drive the entire transmission belt assembly to perform synchronous opening and closing movements of clamping or releasing relative to the discharge pipe to accommodate packaging film rolls of different widths. The slide rod of the electric slide assembly is fixedly connected to the support base.

[0011] Preferably, the longitudinal sealing frame assembly consists of a longitudinal sealing frame body, a sliding frame, and a longitudinal sealing plate. The longitudinal sealing frame body is fixedly connected to the front side wall of the supporting base frame. The sliding frame is slidably connected to the inner side wall of the longitudinal sealing frame body. The longitudinal sealing frame body is engraved with a scale for marking the position of the sliding frame. Each outer side wall of the sliding frame is rotatably connected to a locking handle. The sliding frame is fixed to the longitudinal sealing frame body through the locking handle. The longitudinal sealing plate is fixedly connected to the rear end of the longitudinal sealing frame body. A heat sealer assembly is installed inside the longitudinal sealing plate. The heat sealer assembly includes a heating rod, a temperature control sensor, and a high-temperature resistant polytetrafluoroethylene heat insulation layer to achieve precise control of the sealing temperature.

[0012] Preferably, the visual counting component further includes a main control module integrated inside the support plate; the two counting cameras correspond to the measuring cups on the quantitative feeding rack, and independently capture images of the material in a measuring cup about to reach the discharge port, and capture images of a material flow currently being discharged from the discharge port; the main control module has a built-in image processing unit and counting judgment logic, the image processing unit is configured with a deep learning-based target detection algorithm to identify and count the material in the static cup and the dynamically falling material, and can distinguish between materials that are stuck, overlapping or in abnormal shapes; the counting judgment logic is configured to: estimate the number of the measuring cup about to be discharged, and if the number is correct, allow it to rotate to the discharge port; at the same time, perform real-time counting verification on the material flow being discharged, and compare the two counting results. When the results are consistent, it is determined that the counting is successful. If the results are inconsistent or abnormal material is identified, a signal is immediately sent to the baffle cylinder to intercept the current material flow and trigger an alarm, thereby forming a closed-loop quality control system.

[0013] (III) Beneficial Effects This invention provides a fully automatic visual counting vertical packaging machine, which has the following beneficial effects: 1. This invention utilizes two counting cameras to image and count full measuring cups at the waiting station and empty measuring cups at the emptying station, respectively. This constructs a precise counting method based on difference calculation, fundamentally solving the problem of insufficient counting accuracy caused by interference in single-vision detection. Specifically, the first camera performs an initial count on full measuring cups approaching the discharge port, and the second camera immediately takes a second picture of the bottom of the cup after discharge to confirm complete emptying. The system calculates the difference between the number of full cups and the number of remaining cups to determine the actual packaging quantity. This method effectively identifies and eliminates incomplete emptying caused by material adhesion or residue buildup, thus minimizing counting errors due to material residue and ensuring absolute accuracy in the quantity of each bag of product.

[0014] 2. This invention combines a rotary quantitative feeding rack with a flexible vibrating feeding mechanism, effectively overcoming the shortcomings of existing technologies such as easy material jamming and breakage. The rotary table drives multiple independent metering cups in a cyclical operation, realizing discrete quantitative feeding of materials and avoiding the risk of blockage caused by conveying large volumes of materials in a single channel. At the same time, the vibrating feeding mechanism uses high-frequency micro-vibration to evenly disperse and slowly move the material on the guide plate. This flexible conveying method greatly reduces the mechanical impact on fragile materials and ensures the integrity of the materials. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a side view of the present invention; Figure 3 This is a schematic diagram of the quantitative feeding rack structure of the present invention; Figure 4 This is a schematic diagram of the vibration frame structure of the present invention; Figure 5 This is a schematic diagram of the longitudinal sealing frame assembly in this invention; Figure 6 This is a schematic diagram of the transmission belt assembly connection in this invention; Figure 7 This is a front view of the present invention.

[0016] The components include: 1. Support base frame; 101. Guide plate; 2. Support top frame; 3. Vibrating frame; 301. Vibrating motor; 302. Support base plate; 303. Support spring; 304. Transmission frame; 4. Hopper assembly; 401. Guide plate; 402. Discharge control valve; 5. Quantitative feeding rack; 501. Rotary motor; 502. Reducer; 503. Measuring cup; 504. Baffle plate; 6. Longitudinal sealing frame assembly; 601. Longitudinal sealing frame body; 602. Sliding frame; 603. Longitudinal sealing plate; 604. Heat sealer assembly; 605. Locking handrail. 7. Transmission belt assembly; 701. Transmission belt body; 702. Driving synchronous pulley; 703. Driven synchronous pulley; 704. Connecting frame; 705. Electric slide assembly; 8. Horizontal sealing and cutting assembly; 9. Sealing frame; 901. Material blocking cylinder; 902. Material blocking partition; 10. Vision counting assembly; 1001. Support plate; 1002. Counting camera; 11. Drive motor; 1101. Transmission box; 1102. Transmission gear; 103. Sliding universal joint; 1104. Transmission housing; 12. Discharge hopper; 1201. Discharge pipe. Detailed Implementation

[0017] 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.

[0018] Example 1: like Figure 1-7 As shown, this embodiment of the invention provides a fully automatic visual counting vertical packaging machine, including a supporting base frame 1, and a supporting top frame 2 fixedly connected to the upper side wall of the supporting base frame 1 by bolts. A hopper assembly 4 is fixedly connected to the upper side wall of the supporting top frame 2 for storing regular materials to be packaged, such as computer keycaps.

[0019] A vibrating frame 3 is elastically connected to the bottom of the supporting top frame 2 via four supporting springs 303. The vibrating frame 3 consists of a vibrating motor 301 and a transmission frame 304. A supporting base plate 302 is installed on the lower side wall of the vibrating motor 301, and the lower end of the supporting base plate 302 cooperates with the supporting springs 303. The output end of the vibrating motor 301 is fixedly connected to the bottom of the guide plate 401 via the transmission frame 304, driving the guide plate 401 to generate high-frequency micro-amplitude vibration. The guide plate 401 is precisely aligned with the discharge port of the hopper assembly 4. A discharge control valve 402 is installed inside the discharge port of the hopper assembly 4 for precise control of material flow.

[0020] A quantitative feeding rack 5 is mounted on the top front side of the support base 1 via a bearing seat. Several through holes are evenly distributed along the circumference of the bottom of the quantitative feeding rack 5, and a measuring cup 503 is fixedly connected to the bottom of each through hole. The quantitative feeding rack 5 is driven to rotate by a rotary motor 501 and a precision planetary reducer 502, ensuring its rotational indexing accuracy and stopping accuracy. A baffle plate 504 is fixedly connected to the upper side wall of the support base 1, and the baffle plate 504 slides against the lower surface of the quantitative feeding rack 5. A discharge port is opened inside the baffle plate 504, and a baffle plate 902 is slidably connected inside the discharge port. The baffle plate 902 is driven by a baffle cylinder 901, and its bottom is embedded with a silicone sealing strip, which can form a seal with the discharge port when closed to prevent dust leakage.

[0021] A support plate 1001 is fixedly connected to the front side wall of the support frame 2. A visual counting component 10 is installed on the upper side wall of the support plate 1001, and two high-resolution counting cameras 1002 are installed on the lower side wall. The two counting cameras 1002 correspond to a fully loaded metering cup 503 that is about to reach the discharge port and a material flow that is currently being discharged at the discharge port, forming a dual image acquisition system.

[0022] A discharge hopper 12 is installed directly below the discharge port, and a discharge pipe 1201 is fixedly connected to the lower end of the discharge hopper 12. Drive belt assemblies 7 are installed on both the left and right sides of the discharge pipe 1201 for clamping and pulling the packaging film. The drive belt assembly 7 consists of a driving synchronous pulley 702, a drive belt body 701, and a driven synchronous pulley 703. The inner side of the drive belt body 701 has double-sided teeth that mesh with the pulleys, while the outer side is a smooth plane for clamping the packaging film. A drive motor 11 is installed inside the support base frame 1, and its output transmits power to the driving synchronous pulley 702 through a transmission box 1101, a pair of helical gears 1102, and a sliding universal joint 103.

[0023] The front side wall of the support frame 1 is also fixedly connected to a longitudinal sealing frame assembly 6 and a transverse sealing and cutting assembly 8. The longitudinal sealing frame assembly 6 continuously seals the longitudinal seams of the packaging film through a heat sealer assembly 604. The transverse sealing and cutting assembly 8 is located directly below the longitudinal sealing frame assembly 6 and uses a hot cutter to perform transverse sealing and cutting separation of the filled packaging bag. A guide plate 101 is fixedly connected inside the support frame 1. Its surface is arc-shaped and covered with a polyurethane shock-absorbing layer to guide and cushion the cut packaging bag.

[0024] Working process: Material is evenly fed from the hopper assembly 4 into the measuring cup 503 on the rotating quantitative feeding rack 5 via the vibrating guide plate 401. When the full measuring cup 503 rotates to the vision station, the first counting camera 1002 performs a static count of the material inside. If the quantity is correct, the measuring cup continues to rotate to the discharge port, the baffle plate 902 opens, and the material falls. At this time, the second counting camera 1002 performs dynamic counting verification on the falling material flow. The main control module of the vision counting assembly 10 compares the two counting results. If they match, it is considered successful; if they do not match, it immediately instructs the baffle cylinder 901 to intercept abnormal material. Qualified material falls into the packaging film through the discharge hopper 12, and then undergoes longitudinal sealing, transverse sealing, and cutting in sequence to form an individual packaging bag. Finally, it is buffered by the guide plate 101 and knocked into the collection basket.

[0025] Example 2 The difference between this embodiment and Embodiment 1 is that the electric slide assembly 705 is replaced by a double-headed cylinder assembly, and the piston rod end of the double-headed cylinder is fixedly connected to the connecting frame 704. Synchronous opening and closing of the transmission belt assembly 7 is achieved through pneumatic drive, resulting in lower cost and suitability for production environments where speed adjustment requirements are not high. Simultaneously, the heating rod of the heat sealer assembly 604 is replaced with a ceramic heating element, which provides faster thermal response and more uniform temperature distribution, making it suitable for thin film materials with higher heat-sealing quality requirements. Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A fully automatic vision-counting vertical packaging machine comprising a supporting chassis (1), characterized in that: The upper side wall of the support chassis (1) is fixedly connected with a support top frame (2), the upper side wall of the support top frame (2) is fixedly connected with a hopper assembly (4), the support top frame (2) is provided with four support springs (303), the upper ends of the four support springs (303) are mounted with a vibrating frame (3), and the output end of the vibrating frame (3) is mounted with a guide plate (401). The top of the support chassis (1) and the front side of the support top frame (2) are mounted with a quantitative material taking frame (5), the bottom of the quantitative material taking frame (5) is provided with a plurality of through holes, the bottom of each through hole is fixedly connected with a measuring cup (503), the upper side wall of the support chassis (1) is fixedly connected with a material blocking plate (504), the inside of the material blocking plate (504) is provided with a material discharging port, and the inside of the material discharging port is slidably connected with a material blocking partition plate (902). The front side wall of the support top frame (2) is fixedly connected with a support plate (1001), the upper side wall of the support plate (1001) is mounted with a visual counting assembly (10), and the lower side wall of the support plate (1001) is mounted with two counting cameras (1002), and the two counting cameras (1002) are located on the two sides of the material discharging port, respectively. The front side wall of the support chassis (1) is fixedly connected with a longitudinal sealing frame assembly (6), and the front side wall of the support chassis (1) and the lower side of the longitudinal sealing frame assembly (6) are provided with a transverse sealing and cutting assembly (8).

2. A fully automatic vision counting vertical packing machine according to claim 1, characterized in that: The inside of the support chassis (1) is fixedly connected with a guide plate (101), the guide plate (101) is located below the transverse sealing and cutting assembly (8), and is used for slowing down the falling of the cut packaging bag.

3. A fully automatic vision counting vertical packing machine according to claim 1, characterized in that: The vibrating frame (3) is composed of a vibrating motor (301) and a transmission frame (304), the lower side wall of the vibrating motor (301) is mounted with a support bottom plate (302), the lower end of the support bottom plate (302) is matched with the support spring (303), the output end of the vibrating motor (301) is fixedly connected with the transmission frame (304), the transmission frame (304) is fixedly connected with the bottom of the guide plate (401), the guide plate (401) is aligned with the discharge port of the hopper assembly (4), and the discharge port of the hopper assembly (4) is internally mounted with a discharge control valve (402).

4. A fully automatic vision counting vertical packing machine according to claim 1, characterized in that: The quantitative material taking frame (5) rotates through the combination of a rotating motor (501) and a speed reducer (502), the output end of the rotating motor (501) is fixedly connected with the input end of the speed reducer (502), the output end of the speed reducer (502) is fixedly connected with the lower side wall center of the quantitative material taking frame (5), the upper side wall of the support base frame (1) and close to the front side is provided with a hole sealing frame (9), the upper side wall of the hole sealing frame (9) is provided with a material blocking cylinder (901), the output end of the material blocking cylinder (901) is fixedly connected with a material blocking partition plate (902), and the material blocking partition plate (902) is used for controlling the closing condition of the discharge port.

5. A fully automatic vision counting vertical packing machine according to claim 1, characterized in that: The inside of the support base frame (1) is provided with a transmission motor (11), the output end of the transmission motor (11) is provided with a transmission box (1101), the right side wall of the transmission box (1101) is provided with a transmission box (1104), the inside of the transmission box (1104) is provided with two transmission gears (1102) meshing with each other, one of the transmission gears (1102) is fixedly connected with the output end of the transmission box (1101), and the right side wall of each transmission gear (1102) is provided with a sliding universal joint (103). The transmission belt assembly (7) is composed of a driving synchronous pulley (702), a transmission belt body (701) and a driven synchronous pulley (703), and the output end of the sliding universal joint (103) is fixedly connected with the driving synchronous pulley (702).

6. A fully automatic vision-counting vertical packing machine according to claim 5, characterized in that: The rear side wall of each transmission belt assembly (7) is provided with a connecting frame (704), the driving synchronous pulley (702) and the driven synchronous pulley (703) are rotatably connected with the connecting frame (704), the driving synchronous pulley (702) and the driven synchronous pulley (703) are meshed with the transmission belt body (701), and the front side wall of the support base frame (1) is provided with two groups of electric sliding table assemblies (705). Each group of electric sliding table assemblies (705) is provided with two output motors, and each output motor is fixedly connected with the connecting frame (704).

7. A fully automatic vision counting vertical packing machine according to claim 1, characterized in that: The longitudinal sealing frame assembly (6) is composed of a longitudinal sealing frame body (601), a sliding frame (602) and a longitudinal sealing plate (603), the longitudinal sealing frame body (601) is fixedly connected with the front side wall of the support base frame (1), the sliding frame (602) is slidably connected with the inner side wall of the longitudinal sealing frame body (601), the outer side wall of each sliding frame (602) is rotatably connected with a locking handrail (605), the sliding frame (602) is fixed with the longitudinal sealing frame body (601) through the locking handrail (605), and the longitudinal sealing plate (603) is fixedly connected with the rear end of the longitudinal sealing frame body (601). The inside of the longitudinal sealing plate (603) is provided with a heat sealing device assembly (604).

8. A fully automatic vision counting vertical packing machine according to claim 1, characterized in that: The visual counter assembly (10) further comprises a master control module integrated inside the support plate (1001); two counter cameras (1002) correspond to the measuring cups (503) on the quantitative material taking rack (5), and independently image collect the material in a measuring cup (503) about to reach the discharge port and the material flow being discharged at the discharge port; the master control module is built-in with an image processing unit and a counting judgment logic, the image processing unit is configured with a target detection algorithm based on deep learning, used to identify and count the material in the static cup and the dynamically falling material, and can distinguish the materials with adhesion, overlap or abnormal shape; the counting judgment logic is configured to pre-count the measuring cup (503) about to discharge, and allow it to rotate to the discharge port if the number is correct; at the same time, the material flow being discharged is counted in real time, and the two counting results are compared, when the results are consistent, it is determined that the counting is successful, if the results are inconsistent or abnormal materials are identified, a signal is immediately sent to the material blocking cylinder (901) to intercept the current material flow and trigger an alarm.

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