Control system and method for mixed type suit packaging machine

Abstract

The invention discloses a control system and method for a mixed type suit packaging machine, and belongs to the technical field of packaging machinery automation control. According to the method, the consistency of a virtual formula and physical connection is automatically verified through the mechanical shaft state recognition subsystem; the visual material arranging feedback subsystem adjusts the material arranging rotating speed and the conveying speed in real time so as to stabilize the material flow; the negative pressure closed-loop monitoring subsystem analyzes negative pressure to establish waveform and stability, and judges that the material succeeds or fails to be sucked or falls off in the midway; and the main controller tracks and marks the abnormal station and directs the standby station to execute compensation or final elimination operation. The problems that in the prior art, formula switching depends on manual work, efficiency is low, errors are prone to occurring, the material arranging process is unstable, the material suction state judgment is not accurate, and online compensation capacity is lacked are solved. According to the invention, formula flexible switching, production adaptive optimization and quality intelligent closed-loop control are realized, the equipment automation level, the production efficiency and the product qualification rate are obviously improved, and material waste is reduced.

Description

Technical Field

[0001] This invention belongs to the field of automated control technology for packaging machinery, specifically a control system and method for a hybrid packaged packaging machine. Background Technology

[0002] Mixed-material packaging machines are widely used in the food, daily chemical, and pharmaceutical industries to combine various materials or different specifications of the same material according to a predetermined formula and package them into the same outer bag. These machines typically include a feeding mechanism, a material handling mechanism, multiple material handling stations (rotary material handling components), and a sealing mechanism. In actual production, it is necessary to frequently change the product formula, i.e., change the types and quantities of materials involved in the combination and their corresponding material handling stations.

[0003] The existing hybrid packaging machine control system has the following main shortcomings:

[0004] First, the flexibility of formula switching is poor and it relies on manual intervention. Traditional equipment configures the effective workstations through physical means (such as installing or disassembling turntable modules and adjusting mechanical limits). Each time the formula is changed, the operator must manually install, disassemble, or adjust the mechanical parts according to the production task sheet. This process is time-consuming, prone to errors, and cannot be automatically verified. There is a risk of starting up after misconfiguration, which may lead to equipment failure or incorrect product installation.

[0005] Second, the material handling process lacks real-time feedback and adaptive adjustment. When materials (such as granules or strips) pass through material handling components like vibrating drums, their flow density may fluctuate due to uneven material intake. Existing technologies typically employ a fixed-speed drive mode or rely on manual adjustment based on operator experience. When the material intake is too dense, it can easily lead to blockage at the material handling component outlet or material accumulation; when the material intake is too sparse, it reduces the overall production cycle time. The lack of closed-loop control based on real-time material status affects production efficiency and stability.

[0006] Third, the judgment of material suction status is not accurate and reliable enough. Existing technologies mostly use vacuum switches or simple pressure threshold switches to monitor the negative pressure of the suction cup, which can only determine whether a vacuum has been established, but cannot effectively distinguish between subtle states such as "no material," "weak material adsorption," and "normal adsorption." For example, for porous or irregularly shaped materials, the vacuum is established slowly, and simple threshold judgment may lead to misjudgment. In addition, there is a lack of effective real-time detection methods for situations where material falls during transportation after suction.

[0007] Therefore, there is an urgent need for a hybrid packaging machine control system that can achieve flexible formula switching, adaptive material handling adjustment, and precise judgment of the absorption state, so as to improve the automation level, production efficiency and product qualification rate of the equipment. Summary of the Invention

[0008] To address the above problems, this invention provides a control system and method for a mixed-type packaged machine, which solves the problems of poor flexibility in formula switching and reliance on manual intervention, lack of real-time feedback and adaptive adjustment in the material handling process, and insufficient accuracy and reliability in judging the material picking status.

[0009] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0010] A control system for a hybrid packaging machine includes: a main controller configured to execute control logic; a vision-based material handling feedback subsystem including a vision sensor disposed above the inner bag conveyor belt and upstream of the rotary material handling assembly, the vision sensor being communicatively connected to the main controller for acquiring material images; a negative pressure closed-loop monitoring subsystem including a digital pressure sensor disposed in the air path of the vacuum suction cup of each rotary material handling assembly, each digital pressure sensor being communicatively connected to the main controller for monitoring the negative pressure data of the corresponding vacuum suction cup; and a mechanical shaft status recognition subsystem including a shaft status sensor disposed at the connection point of each connecting shaft assembly, each shaft status sensor being communicatively connected to the main controller for... The system detects the connection or disconnection status of the corresponding connecting shaft assembly; it executes and drives the module, including a rotary drum drive motor controller, a conveyor belt drive controller, and valve island controllers for the rotary cylinder and material transfer cylinder of each turntable material transfer assembly, all connected to the main controller. The main controller is configured to: adjust the rotational speed of the rotary drum drive motor based on image data acquired by a vision sensor; determine whether material extraction was successful or failed based on negative pressure data monitored by a digital pressure sensor; verify the status detected by all shaft status sensors against the requirements of a preset virtual formula; and control the execution and drive module to perform corresponding start, stop, compensation, or rejection operations based on the verification results and / or the material extraction failure judgment results.

[0011] Furthermore, in the mechanical shaft status recognition subsystem, the shaft status sensor is a Hall sensor or a photoelectric switch, and its setting position corresponds to the limiting notch area of ​​the connecting shaft in the connecting shaft assembly, used to sense the insertion or removal status of the connecting shaft.

[0012] Furthermore, the virtual recipe defines the set of numbered target turntable transfer components that need to be enabled.

[0013] Furthermore, the main controller is also configured to check for the existence of an idle backup turntable transfer component after determining that the current pickup has failed; if so, it controls the backup turntable transfer component to perform supplementary pickup and delivery operations when the chain grid moves to its station, and clears the defective product label. .

[0014] A control method for a mixed-type packaged machine includes: S1: System initialization, reading preset virtual formula parameters; S2: Performing a self-check of the mechanical axis status, comparing the actual status of each connected axis with the requirements of the virtual formula parameters; if inconsistent, an alarm is triggered and the equipment is locked; if consistent, proceed to the next step; S3: Starting the packaging process, adaptively adjusting the rotation speed of the rotary feeding component based on image data from the visual feeding feedback subsystem; S4: For each activated rotary feeding component, determining whether material feeding is successful based on data from the negative pressure closed-loop monitoring subsystem when it performs a suction action; S5: If suction failure is determined in step S4, marking the corresponding feed chain grid as abnormal and tracking the chain grid; S6: When the marked abnormal chain grid reaches a preset station, performing a rejection or compensation operation.

[0015] Further, step S2 specifically includes: S21: Define a virtual recipe function Recipe(ID), where ID is the number of the turntable material transfer component. When Recipe(ID)=1, it indicates that the recipe requires the turntable material transfer component with the number ID to be enabled. When Recipe(ID)=0, it indicates that it is not enabled. S22: Define an axis state function Shaft(ID). The axis state sensor detects the connection. When Shaft(ID)=1, it indicates that the connecting axis corresponding to the turntable material transfer component with the number ID is in the connected state. When Shaft(ID)=0, it indicates that it is in the disconnected state. S23: For each ID, compare the values ​​of Recipe(ID) and Shaft(ID). S24: If there exists any ID such that Recipe(ID)≠Shaft(ID), the verification is determined to be unsuccessful, and an alarm and lock are executed.

[0016] Furthermore, in step S3, the main controller acquires a real-time image of the inlet area of ​​the rotary drum material handling assembly through the vision sensor; calculates the ratio of the material pixel area to the total image area in the real-time image, defining it as the real-time flow density value D; and compares the real-time flow density value D with a preset high-density threshold. and low density threshold Compare; if D> If D < 0, then increase the set speed of the rotary drum drive motor and decrease the drive speed of the inner bag conveyor belt; if D < 0. If the rotation speed setting of the rotary drum drive motor is reduced, the driving speed of the inner bag conveyor belt will be increased.

[0017] Furthermore, the adaptive adjustment of the rotational speed of the rotary drum material handling component in step S3 is specifically PID control, including: calculating the real-time flow density value D and the preset desired flow density value. The deviation e, e= –D; Based on the deviation e, the speed adjustment of the drum drive motor is calculated using proportional, integral, and differential methods. The speed adjustment amount Superimposed on the motor's base speed setting value Get the current speed command. = + .

[0018] Furthermore, step S4, determining whether the material has been successfully absorbed, includes the following sub-steps:

[0019] S41: At time t0, the vacuum is turned on and the negative pressure value P(t) is monitored.

[0020] S42: Record the first time the negative pressure value P(t) reaches the preset threshold. Time t1;

[0021] S43: Calculate the time difference =t1–t0;

[0022] S44: If If X is a preset time threshold, then the absorption is determined to have failed.

[0023] S45: During the lifting process, if the negative pressure value P(t) exceeds the preset range without receiving a vacuum breaking command, If the material rebounds, it is determined that the material has fallen midway and is marked as a failure to absorb it.

[0024] Furthermore, step S5 specifically involves: if step S4 determines that a certain turntable material transfer component fails to pick up a specific feed chain grid at a specific station, the main controller immediately marks that chain grid with a defective identifier. The main controller began tracking the carrier. The displacement of the marked chain grid on the feeding mechanism.

[0025] The beneficial effects of this invention are as follows: Real-time production line status data is collected through vision, pressure, and position sensors. The main controller performs logical analysis and decision-making, dynamically adjusting the action parameters and coordination timing of the actuators to form an intelligent control closed loop of perception, decision-making, and execution. This achieves intelligent monitoring and closed-loop control of the entire packaging process, effectively preventing packaging defects and formula errors caused by leakage or incorrect shaft connections, thus improving production flexibility and product quality stability. Non-contact sensors accurately capture the physical position of mechanical shafts, converting manual operation states into digital signals recognizable by the controller, providing a reliable foundation for achieving hardware and software interlocking.

[0026] By comparing software-defined recipe requirements (virtual state) with hardware sensor feedback (physical state) in real time, consistency verification is performed before equipment startup. In case of inconsistency, forced intervention is initiated by interrupting the startup process and triggering an alarm. Based on machine vision technology, the density of material flow is quantified in real time, and the speed of key actuators is dynamically adjusted through a closed-loop feedback control algorithm, causing the system output to tend towards the desired stable state. Using dual criteria of "setup time" and "pressure mutation," the system can more comprehensively and reliably identify two typical suction failure modes: "failure to pick up" and "dropping after pick-up," further improving the coverage and accuracy of quality inspection. Attached Figure Description

[0027] Figure 1 This is a block diagram of a control system for a hybrid package packaging machine;

[0028] Figure 2 This is a flowchart of a control method for a hybrid packaged packaging machine. Detailed Implementation

[0029] To enable those skilled in the art to better understand the technical solution, the present invention will be described in detail below with reference to embodiments. The description in this part is only exemplary and explanatory, and should not be used to limit the scope of protection of the present invention in any way.

[0030] Example 1

[0031] This embodiment describes a control system for a hybrid packaging machine. The system is applied to a packaging machine comprising a feeding mechanism, an inner bag conveyor belt, a rotary feeding assembly, a temporary storage unit, and multiple rotary feeding assemblies connected in series via connecting shaft assemblies.

[0032] See attached document Figure 1 A control system for a hybrid packaged packaging machine includes: a main controller configured to execute control logic; preferably, the main controller is an industrial programmable logic controller (PLC).

[0033] The visual material handling feedback subsystem includes a visual sensor positioned above the inner bag conveyor belt and upstream of the rotary drum material handling assembly. The visual sensor is communicatively connected to the main controller and is used to acquire material images. Preferably, the visual material handling feedback subsystem consists of an area array industrial camera and its light source mounted above the conveyor belt and directly above the rotary drum inlet. The lens is perpendicularly oriented towards the surface of the conveyor belt, and the camera communicates with the PLC via Ethernet.

[0034] The negative pressure closed-loop monitoring subsystem includes digital pressure sensors installed in the air path of the vacuum suction cup of each rotary material transfer assembly. Each digital pressure sensor is communicatively connected to the main controller and is used to monitor the negative pressure data of the corresponding vacuum suction cup. Preferably, the negative pressure closed-loop monitoring subsystem includes three digital pressure sensors, which are connected in series in the air path of the vacuum suction cup of each of the three rotary material transfer assemblies, located on the pipeline between the vacuum generator and the suction cup. The sensor signals are connected to the analog input module of the PLC.

[0035] The mechanical axis status recognition subsystem includes axis status sensors installed at the connection points of each connecting axis assembly. Each axis status sensor is communicatively connected to the main controller and is used to detect the connection or disconnection status of the corresponding connecting axis assembly. Preferably, the mechanical axis status recognition subsystem consists of three pairs of diffuse reflection photoelectric switches. The transmitter and receiver of each pair of switches are positioned opposite each other on both sides of the limiting notch of the connecting axis. When the connecting axis is inserted into place, the notch aligns with the light path, the light passes through, and the sensor outputs a high-level signal to indicate "connection". When the axis is pulled out, the light path is blocked by the axis body, and a low-level signal is output to indicate "disconnection". The sensor signal is connected to the analog input module of the PLC.

[0036] The execution and drive module includes a rotary drum drive motor controller, a conveyor belt drive controller, and valve island controllers for the rotary cylinder and material transfer cylinder of each rotary material transfer assembly connected to the main controller; preferably, the execution and drive module includes a frequency converter for controlling the rotary drum motor, a servo driver for controlling the conveyor belt, and an electromagnetic valve island for controlling each cylinder, all of which are controlled by the digital output module of the PLC.

[0037] The main controller is configured to: adjust the rotation speed of the drum drive motor based on image data collected by the vision sensor; determine whether the material is successfully or unsuccessfully picked up based on the negative pressure data monitored by the digital pressure sensor; verify the status detected by all shaft status sensors against the requirements of the preset virtual formula; and control the execution and drive modules to perform corresponding start, stop, compensation, or rejection operations based on the verification results and / or the material picking failure judgment results.

[0038] In the mechanical shaft status recognition subsystem, the shaft status sensor is a Hall sensor or a photoelectric switch, and its setting position corresponds to the limiting notch area of ​​the connecting shaft in the connecting shaft assembly, used to sense the insertion or removal status of the connecting shaft.

[0039] The main controller is also configured to check for an idle backup turntable transfer assembly after determining that the current pick-up has failed; if so, it controls the backup turntable transfer assembly to perform a supplementary pick-up and delivery operation when the chain grid moves to its station, and clears the defective product label. .

[0040] Example 2

[0041] This embodiment describes a control method for a hybrid packaged packaging machine. (Refer to the attached document.) Figure 2 This includes the following steps:

[0042] Step S1: System initialization, main controller power-on, and reading preset virtual recipe parameters from the HMI. The virtual recipe parameters define the set of target rotary material transfer components that need to be activated for the current production task. The virtual recipe is represented by a recipe function Recipe(ID), where ID is the unique number of the rotary material transfer component. When Recipe(ID) equals 1, it indicates that the current recipe requires the activation of the rotary material transfer component with ID; when Recipe(ID) equals 0, it indicates that the current recipe does not activate the rotary material transfer component with that ID. Simultaneously, the system loads various control parameters, including the expected value of the visual flow density. High density threshold Low density threshold Negative pressure judgment threshold and time threshold X, and the base speed of each drive motor. .

[0043] Step S2: Perform self-check and verification of the mechanical axis status. The main controller executes the following specific verification process:

[0044] S21: Define the virtual recipe function. The main controller reads the preset virtual recipe from the storage unit, denoted as Recipe(ID). The parameter ID is the number of the turntable material transfer component. The function value rule is: when the value of Recipe(ID) is 1, it means that the current production recipe requires the turntable material transfer component with the number ID to be enabled; when the value of Recipe(ID) is 0, it means that the current recipe does not enable the component with that number. S22: Define and obtain the physical axis status function. The main controller reads the real-time digital signal of the axis status sensor in each mechanical axis status recognition subsystem in a loop, and defines the axis status function Shaft(ID) based on the signal. For the workstation with the number ID, when its corresponding connecting axis component is fully inserted and locked in place, the main controller determines that the value of Shaft(ID) is 1; when the connecting axis component is pulled out or not fully inserted, the value of Shaft(ID) is determined to be 0.

[0045] S23: Perform item-by-item comparison and verification. The main controller iterates through all ID numbers and performs a logical comparison between the value of Recipe(ID) and the value of Shaft(ID).

[0046] S24: Execute control instructions based on the comparison results. If for all IDs, the value of Recipe(ID) equals the value of Shaft(ID), the main controller determines that the verification passes. If there exists at least one ID such that the value of Recipe(ID) is not equal to the value of Shaft(ID), the main controller immediately determines that the verification fails. After verification failure, the main controller triggers an audible and visual alarm through the human-machine interface (HMI) and sends a global lock command to prevent all drive components from starting.

[0047] If the verification passes, the device enters the ready state and is allowed to start.

[0048] Step S3: Start the packaging process and execute adaptive material handling control based on visual flow density.

[0049] The main controller starts the rotary drum drive motor and the inner bag conveyor belt driver. The vision sensor of the vision feeding feedback subsystem begins to acquire real-time images of the inlet area of ​​the rotary drum feeding assembly at a fixed frequency and transmits the image data to the main controller.

[0050] The main controller processes each frame of real-time image: first, it binarizes the image to distinguish between the material area and the background area; then it calculates the total area of ​​all material pixels in the image, divides the total area by the total pixel area of ​​the image, and obtains the real-time flow density value D.

[0051] The main controller compares the real-time flow density value D with the preset high-density threshold. and low density threshold Compare the results and adjust the speed accordingly:

[0052] If the real-time flow density value D is greater than the high density threshold This indicates that the incoming material is too dense. The main controller increases the speed setting of the rotary drum drive motor and reduces the drive speed of the inner bag conveyor belt to accelerate material dispersion and slow down material outflow to prevent blockage.

[0053] If the real-time flow density value D is less than the low density threshold This indicates that the incoming material is sparse. The main controller reduces the speed setting of the rotary drum drive motor and increases the drive speed of the inner bag conveyor belt to reduce unnecessary material handling actions and speed up the process.

[0054] If the real-time flow density value D is within the low density threshold and high density threshold In between, the current speed setting will be maintained.

[0055] The adjustment process is implemented using a PID control algorithm. Specifically, it involves calculating the real-time flow density value D and the desired flow density value. The deviation e, e equals Subtract D. Based on this deviation e, the speed adjustment of the drum drive motor is obtained through calculations using proportional, integral, and differential terms. Finally, the speed adjustment amount... Superimposed on the motor's base speed setting value Get the current speed command. , = + The speed of the inner bag conveyor belt is adjusted in reverse according to the same logic.

[0056] In this embodiment, the real-time flow density D calculated by the vision system is used as a process variable (PV). The setpoint (SP) is... =0.45. A PID control loop is configured in the PLC with the following parameters: proportional gain Kp=15, integral time Ti=2.0 seconds, and derivative time Td=0.5 seconds.

[0057] At time t1, D=0.55 is detected. The PID controller calculates the deviation e=SP-PV=0.45-0.55=-0.10.

[0058] According to the formula: Output adjustment amount =Kp*e+(Kp / Ti)*∫edt+Kp*Td*de / dt.

[0059] After calculation, we obtained =-3.2 (units correspond to speed increments). Current base speed of the drum motor. The frequency is 30Hz. Therefore, the output speed command is... =30 + (-3.2) = 26.8Hz. The PLC sets the inverter frequency to 26.8Hz. Simultaneously, as an auxiliary adjustment, the PLC synchronously reduces the conveyor belt speed by 8%.

[0060] At time t2, the material is sparse, and D = 0.30. At this time, the deviation e = 0.45 - 0.30 = 0.15. This is calculated using PID control. =+4.8, =30 + 4.8 = 34.8 Hz. The PLC increases the drum speed to 34.8 Hz and increases the conveyor belt speed by 10%. Through continuous adjustment of the PID controller, the flow density D is stabilized at around 0.45.

[0061] Step S4: Determine the success or failure of material suction based on negative pressure waveform analysis. For each rotary material transfer component activated according to the virtual formula, the main controller monitors the negative pressure change of its vacuum suction cup through the negative pressure closed-loop monitoring subsystem during its single material suction cycle.

[0062] The specific sub-steps for judgment are as follows:

[0063] S41: At the precise moment t0 when the transfer cylinder is pressed down and the vacuum valve is opened, the main controller starts to continuously read the negative pressure value P(t) returned by the corresponding digital pressure sensor.

[0064] S42: The main controller monitors the change in negative pressure value P(t) in real time, recording its first drop from the initial value (usually atmospheric pressure) to the preset negative pressure threshold. Time t1. Negative pressure threshold. This is an empirical value representing the negative pressure level sufficient to reliably adsorb the material.

[0065] S43: Calculate the time difference , This time difference equals t1 minus t0. This reflects the speed at which the vacuum pipeline establishes an effective adsorption negative pressure.

[0066] S44: The main controller will calculate the time difference. Compare with a preset time threshold X. The time threshold X represents the normal maximum time required to establish effective adsorption. If... If the time threshold X is exceeded, the absorption is considered to have failed because the adsorption is too slow or an effective seal has not been formed, which may correspond to no material or abnormal material shape.

[0067] S45: During the process of suction completion and material lifting by the transfer cylinder, the main controller continuously monitors the negative pressure value P(t). If, without receiving a vacuum breaking command, the negative pressure value P(t) exceeds a preset range... If the temperature suddenly rises, it is determined that the material fell during the handling process, and the current suction operation is marked as a failure.

[0068] Step S5: Extract and track failed flags.

[0069] If step S4 determines that a turntable material transfer component fails to pick up a specific feed chain grid at a specific station, the main controller immediately marks that chain grid with a defective identifier. At the same time, the main controller began tracking the carrier. The displacement of the marked chain slots on the feeding mechanism. The position of each chain slot on the feeding mechanism is precisely located by encoder signals.

[0070] Step S6: Perform the removal or compensation operation.

[0071] The main controller performs one of the following two operations based on preset logic and system resource conditions:

[0072] Elimination operation: The main controller continuously tracks the carrier The chain slot is marked. When this chain slot moves to the preset outer bag filling station, the main controller sends a blocking signal to the filling machine's controller, and the filling machine skips the outer bag filling operation for that chain slot. Subsequently, the unfilled outer bag is rejected as an empty bag or a defective product in subsequent processes.

[0073] Compensation Operation: If the system has an idle backup rotary feeder component (i.e., a component with Recipe(ID) of 0 but Shaft(ID) of 1), the main controller checks for the existence of such a backup component after determining that the pick-up has failed. If it exists, the main controller will plan a replacement pick-up task. (Tracking and carrying...) When a marked chain slot moves to the station corresponding to the standby turntable material transfer component, the main controller controls the standby component to perform a replenishment and delivery operation. If the replenishment is successful (confirmed by negative pressure waveform analysis), the main controller clears the chain slot. The device is marked so that it can proceed normally into the subsequent filling process; if the re-absorption still fails, it is marked again and finally the rejection operation is performed.

[0074] It should be noted that, in this document, the terms "comprising," "including," and any other variations are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Specific examples have been used in this document to illustrate the principles and implementation methods of the present invention. These examples are merely for the purpose of helping to understand the method and core ideas of the present invention. The above descriptions are only preferred embodiments of the present invention. It should be pointed out that, due to the limitations of written expression and the objective existence of infinite specific structures, those skilled in the art can make several improvements, modifications, or variations without departing from the principles of the present invention, and can also combine the above technical features in an appropriate manner. These improvements, modifications, variations, or combinations, or the direct application of the concept and technical solution of the present invention to other situations without modification, should all be considered within the scope of protection of the present invention.

Claims

1. A control system for a hybrid wrap-around packaging machine, characterized in that, The application relates to a packaging system, comprising: a main controller configured to execute control logic; a visual material sorting feedback subsystem comprising a visual sensor in communication with the main controller for collecting material images; a negative pressure closed loop monitoring subsystem comprising a digital pressure sensor in communication with the main controller for monitoring negative pressure data of corresponding vacuum cups; a mechanical shaft state identification subsystem comprising shaft state sensors in communication with the main controller for detecting the connection or disconnection state of corresponding connecting shaft assemblies; an execution and driving module comprising a drum driving motor controller, a conveyor belt driving controller and a valve island controller connected to the main controller; wherein the main controller is configured to: adjust the rotation speed of the drum driving motor based on the image data collected by the visual sensor; judge whether material suction is successful or failed based on the negative pressure data monitored by the digital pressure sensor; check the requirements of a preset virtual formula based on the states detected by all the shaft state sensors; control the execution and driving module to perform corresponding start, stop, compensation or rejection operations based on the checking result and the material suction failure judgment result.

2. A control system for a hybrid wrap-around packaging machine according to claim 1, characterized in that, The shaft state sensor is a Hall sensor or a photoelectric switch, which is arranged at a position corresponding to a limiting gap region of a connecting shaft in the connecting shaft assembly, and is used for sensing the insertion or extraction state of the connecting shaft.

3. A control system for a hybrid wrap-around packaging machine according to claim 1, characterized in that, The virtual formula defines a set of numbers of target turntable material transfer assemblies that need to be enabled.

4. A control system for a hybrid wrap-around packaging machine according to claim 1, characterized in that, The main controller is further configured to, after determining that the current suction fails, check whether there is a standby carousel material transferring assembly in an idle state; if there is, control the standby carousel material transferring assembly to perform a make-up suction and dropping operation when the chain grid moves to its working position, and clear the defective product mark .

5. A control method for a hybrid wrap-around packaging machine, characterized in that, The application further relates to a packaging method, comprising the following steps: S1: system initialization, reading preset virtual formula parameters; S2: performing a mechanical shaft state self-check, comparing the actual state of each connecting shaft detected with the requirements of the virtual formula parameters, and if they are inconsistent, alarming and locking the equipment, and if they are consistent, entering the next step; S3: starting the packaging process, and based on the image data of the visual material sorting feedback subsystem, adaptively adjusting the rotation speed of the drum material sorting assembly; S4: for each enabled turntable material transfer assembly, when it performs a suction action, judging whether material suction is successful based on the data of the negative pressure closed loop monitoring subsystem; S5: if it is judged in step S4 that suction fails, marking the current corresponding feeding chain grid as abnormal, and tracking the chain grid; S6: when the chain grid marked as abnormal reaches a preset station, performing a rejection or compensation operation.

6. A control method for a hybrid wrap-around packaging machine according to claim 5, characterized in that, The step S2 specifically comprises: S21: defining a virtual formula function Recipe (ID), wherein ID is the number of a turntable material transfer assembly, when Recipe (ID) = 1, it indicates that the formula requires enabling the turntable material transfer assembly with the number ID, and when Recipe (ID) = 0, it indicates that it is not enabled; S22: defining a shaft state function Shaft (ID) detected by a shaft state sensor, when Shaft (ID) = 1, it indicates that the connecting shaft corresponding to the turntable material transfer assembly with the number ID is in a connected state, and when Shaft (ID) = 0, it indicates that it is in a disconnected state; S23: comparing the values of Recipe (ID) and Shaft (ID) for each ID. S24: If there exists any ID such that Recipe(ID) ≠ Shaft(ID), then the verification is deemed to have failed, and an alarm and lock are executed.

7. A control method for a hybrid wrap-around packaging machine according to claim 5, characterized in that, The main controller in the step S3 acquires real-time images of the inlet area of the drum sorting assembly through the visual sensor; calculates the ratio of the pixel area of the material in the real-time images to the total area of the images, which is defined as a real-time flow density value D; compares the real-time flow density value D with preset high-density threshold value and low-density threshold value ; if D , increases the rotation speed setting value of the drum driving motor and reduces the driving speed of the inner bag conveying belt; if D , reduces the rotation speed setting value of the drum driving motor and increases the driving speed of the inner bag conveying belt.

8. A control method for a hybrid wrap-around packaging machine according to claim 5, characterized in that, The adaptive adjustment of the rotating speed of the rotating drum sorting assembly in the step S3 is specifically PID adjustment, including: calculating the deviation e of the real-time flow density value D and the preset expected flow density value ; according to the deviation e, the rotating speed adjustment amount of the rotating drum driving motor is calculated through proportion, integration and differentiation ; the rotating speed adjustment amount is superimposed on the basic rotating speed setting value of the motor to obtain the current rotating speed instruction = + .​​ 9. A control method for a hybrid wrap-around packaging machine according to claim 5, characterized in that, The step S4, which determines whether the material has been successfully absorbed, includes the following sub-steps: S41: At time t0, the vacuum is turned on and the negative pressure value P(t) is monitored. S42: record the time t1 when the negative pressure value P(t) reaches the preset threshold value for the first time S42: record the time t1 when the negative pressure value P(t) reaches the preset threshold value for the first time S43: Calculate the time difference = t1 - t0; S44: if X, wherein X is a preset time threshold, it is determined that the current suction fails; S45: In the lifting process, if it is monitored that the negative pressure value P(t) rises more than a preset amplitude without receiving a break vacuum command, it is determined that the material falls in the middle of the way, and marked as a suction failure. S45: In the lifting process, if it is monitored that the negative pressure value P(t) rises more than a preset amplitude without receiving a break vacuum command, it is determined that the material falls in the middle of the way, and marked as a suction failure.

10. A control method for a hybrid wrap-around packaging machine according to claim 5, characterized in that, The step S5 is specifically: if the rotary table material transferring assembly fails to suck the specific feed chain grid in the specific station, the main controller immediately marks a defective product mark for the chain grid , and the main controller starts tracking the displacement of the chain grid carrying the mark on the feeding mechanism .

Images