Multi-sensor fused intelligent sorting system of color sorter

Abstract

The invention is applicable to the technical field of color sorters, and provides a multi-sensor fused intelligent sorting system of a color sorter, which comprises two vertically arranged and mutually symmetrical side brackets, a screening mechanism, a first-stage guide plate mechanism and a second-stage guide plate mechanism, the screening mechanism, the first-stage material guide plate mechanism and the second-stage material guide plate mechanism are sequentially arranged between the two side supports from top to bottom. According to the multi-sensor fused intelligent sorting system of the color sorter, by arranging the CCD camera module, the near infrared spectrum sensor module and the laser distance measuring sensor array, the CCD camera module, the near infrared spectrum sensor module and the laser distance measuring sensor array are fused and applied, so that multi-sensor cooperative detection is realized; the multi-dimensional detection requirements of material surface color texture, internal component characteristics, three-dimensional size form and the like are comprehensively covered, the accuracy and coverage rate of unqualified material identification are improved, and the detection stability under complex working conditions is guaranteed through stable illumination supply and dustproof and anti-vibration installation design of the sensor.

Description

Technical Field

[0001] This invention belongs to the field of color sorter technology, and particularly relates to an intelligent sorting system for color sorters that integrates multiple sensors. Background Technology

[0002] Color sorters are intelligent material sorting devices based on optical detection principles, integrating multi-sensor recognition and precise airflow sorting technology. They are widely used in industries such as grain, ore, plastics, traditional Chinese medicine, and food. Their core function is to quickly separate unqualified products from qualified products in large quantities. The workflow is as follows: materials are evenly distributed on a conveyor belt or fall along a slide by a vibrating feeder. A CCD camera collects data such as the color and shape of the materials, and the intelligent control system quickly analyzes and determines whether the materials are qualified or not. When unqualified materials are detected, the corresponding jet valve group is immediately triggered, and high-pressure airflow "blows" them into the unqualified product collection bin. Qualified materials enter the finished product bin along the original trajectory, ultimately achieving efficient and high-precision automated sorting, significantly improving material purity and production efficiency, and reducing manual sorting costs.

[0003] Color sorters are now used in many industries such as grain, ore, and plastics. Most current color sorters use CCD cameras as the core to visually inspect materials. They can only capture surface features of materials and cannot identify internal defects and compositional differences. The detection dimension is single and they are easily affected by light fluctuations and material surface reflections. They have weak anti-interference capabilities and limited ability to identify three-dimensional morphological abnormalities and minor defects. They cannot adapt to complex scenarios and cannot meet the sorting needs of high purity, multiple categories, and complex environments. Summary of the Invention

[0004] This invention provides a multi-sensor fusion intelligent sorting system for color sorters, aiming to solve the problem that most current color sorters rely on CCD cameras for visual inspection of materials, which makes it difficult to meet the sorting requirements of high purity, multiple categories, and complex environments.

[0005] The present invention is implemented as follows: a multi-sensor fusion color sorter intelligent sorting system includes two vertically arranged and symmetrical side supports, a screening mechanism, a primary guide plate mechanism and a secondary guide plate mechanism;

[0006] The screening mechanism, the primary guide plate mechanism, and the secondary guide plate mechanism are arranged sequentially from top to bottom between the two side supports. Two fixed horizontal plates are horizontally fixedly connected between the two side supports and on both sides of the separation section between the primary and secondary guide plate mechanisms. Light strips are horizontally fixedly connected to the inner surfaces of the multiple fixed horizontal plates. Two open-end mounting frames are horizontally fixedly connected between the two fixed horizontal plates on the same side. A CCD camera module and a near-infrared spectral sensor module are respectively installed inside the two mounting frames. A horizontal mounting frame is horizontally fixedly connected between the two side supports and at the front of the lower end of the secondary guide plate mechanism. A laser rangefinder sensor array is installed on the rear surface of the horizontal mounting frame.

[0007] Preferably, the front of the two side brackets is fixedly connected to a device frame, an execution unit is disposed inside the device frame, and a control panel is disposed on the front surface of the device frame.

[0008] Preferably, the screening mechanism includes a horizontally arranged feed frame with open top and bottom. The front and rear surfaces of the feed frame are provided with multiple vertically arranged and corresponding through slots. The middle of the inner cavity of the feed frame is rotatably connected to a rotating shaft arranged along its length. Screening strips are fixedly connected to both sides of the outer surface of the rotating shaft. The multiple screening strips on both sides correspond to the multiple through slots on both sides. The outer ends of the multiple screening strips extend to the outside of the corresponding through slots.

[0009] Preferably, one end of the rotating shaft rotatably passes through one side surface of the feed frame and extends outward. A driven synchronous pulley is fixedly connected to the outer surface of the rotating shaft outside the feed frame. A connecting frame is fixedly connected to the lower part of the same side surface of the feed frame. A bidirectional motor is fixedly connected to the outer end of the connecting frame. A driving synchronous pulley is fixedly connected to the output shaft surface of the bidirectional motor. The driving synchronous pulley and the driven synchronous pulley are connected by belt drive.

[0010] Preferably, multiple connecting blocks are horizontally fixedly connected to the upper part of both sides of the feed frame, and shock-absorbing springs are vertically fixedly connected to the bottom of the multiple connecting blocks. Connecting plates are horizontally fixedly connected to the bottom of the multiple shock-absorbing springs. The connecting plates on both sides are respectively fixedly connected to the inner surfaces of the two side supports. A vibration motor is provided on the outer surface of the feed frame.

[0011] Preferably, the primary guide plate mechanism includes a first plate body inclinedly disposed in the middle between the two side uprights. A plurality of first distributing cylinders are fixedly connected to the upper part of the front surface of the first plate body, which are evenly spaced along its length and gradually decrease in size from the inner radial direction downward. A plurality of diversion channels corresponding to the plurality of first distributing cylinders are vertically fixedly connected to the lower part of the front surface of the first plate body. A receiving hopper extending to the bottom opening of the feed frame is fixedly connected to the top of the first plate body.

[0012] Preferably, the secondary guide plate mechanism includes a second plate that is inclined between the two side supports and located below and behind the first plate with the same inclination angle. A plurality of second distribution cylinders are fixedly connected to the front surface of the second plate, which are evenly spaced along its length and gradually decrease in size in the inner radial direction. The plurality of second distribution cylinders correspond to the plurality of first distribution cylinders in position.

[0013] Preferably, a sorting execution structure is horizontally fixedly connected between the two side uprights and at the upper and lower parts of the secondary guide plate mechanism.

[0014] Beneficial effects

[0015] Compared with the prior art, the beneficial effects of the present invention are: the present invention provides a multi-sensor fusion intelligent sorting system for color sorters.

[0016] (1) The intelligent sorting system of the color sorter with multi-sensor fusion, by setting up a CCD camera module, a near-infrared spectral sensor module and a laser ranging sensor array, integrates the CCD camera module, the near-infrared spectral sensor module and the laser ranging sensor array together to realize multi-sensor collaborative detection. It not only fully covers the multi-dimensional detection needs such as the color texture of the material surface, the internal composition characteristics and the three-dimensional size and shape, but also improves the accuracy and coverage of the identification of unqualified materials. Furthermore, the stable light supply and the dustproof and vibration-proof installation design of the sensors ensure the detection stability under complex working conditions.

[0017] (2) The multi-sensor fusion color sorter intelligent sorting system sets up a primary guide plate mechanism and a secondary guide plate mechanism. The system guides the material through the primary guide plate mechanism and the secondary guide plate mechanism. Both mechanisms are equipped with multiple cylindrical structures whose inner diameter gradually decreases from top to bottom. When the material falls, it falls into the interior of multiple cylindrical structures. Since the diameter of the cylindrical structure gradually decreases from top to bottom, the material discharged from the bottom of the cylindrical structure can be more dispersed and will not fall together in a pile. This avoids the material from piling up and affecting the visual detection of the material, and further improves the accuracy and coverage of the identification of unqualified materials. Attached Figure Description

[0018] Figure 1This is a schematic diagram of the internal structure of the present invention;

[0019] Figure 2 This is a schematic diagram of the overall structure of the present invention;

[0020] Figure 3 This is a schematic diagram of the screening mechanism in this invention;

[0021] Figure 4 This is a schematic diagram of the structure of the two guide plate mechanisms in this invention;

[0022] Figure 5 This is a schematic diagram of the distribution structure of the two guide plate mechanisms in this invention.

[0023] In the diagram: 1-Side support, 2-Screening mechanism, 21-Feed frame, 22-Through slot, 23-Rotating shaft, 24-Screening bar, 25-Driven synchronous pulley, 26-Connecting frame, 27-Bidirectional motor, 28-Driven synchronous pulley, 29-Connecting block, 210-Shock-absorbing spring, 211-Connecting piece, 3-First-stage guide plate mechanism, 31-First plate, 32-First distributing cylinder, 33-Diversion channel, 34-Receiving hopper, 4-Second-stage guide plate mechanism, 41-Second plate, 42-Second distributing cylinder, 5-Fixed horizontal plate, 6-Mounting frame, 7-Hollow slot, 8-Horizontal mounting frame, 9-Sorting execution structure. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0025] Please see Figure 1-5 The present invention provides a technical solution: a multi-sensor fusion color sorter intelligent sorting system, including two vertically arranged and symmetrical side supports 1, a screening mechanism 2, a primary guide plate mechanism 3 and a secondary guide plate mechanism 4;

[0026] The screening mechanism 2, the primary guide plate mechanism 3, and the secondary guide plate mechanism 4 are arranged sequentially from top to bottom between two side supports 1. Two fixed horizontal plates 5 are horizontally fixedly connected between the two side supports 1 and on both sides of the separation section between the primary guide plate mechanism 3 and the secondary guide plate mechanism 4. Light strips are horizontally fixedly connected to the inner surfaces of the multiple fixed horizontal plates 5. Two installation frames 6 with open inner ends are horizontally fixedly connected between the two fixed horizontal plates 5 on the same side. CCD camera modules and near-infrared spectral sensor modules are respectively installed inside the two installation frames 6. A horizontal mounting frame 8 is horizontally fixedly connected between the two side supports 1 and at the front of the lower end of the secondary guide plate mechanism 4. A laser rangefinder sensor array is installed on the rear surface of the horizontal mounting frame 8.

[0027] The front of the two side brackets 1 is fixedly connected to the outer frame 10 of the device. The execution unit is arranged inside the outer frame 10, and the control panel 11 is arranged on the front surface of the outer frame 10.

[0028] A sorting execution structure 9 is horizontally fixedly connected between the two side uprights 1 and at the upper and lower parts of the secondary guide plate mechanism 5.

[0029] In this embodiment, the system integrates a CCD camera module, a near-infrared spectral sensor module, and a laser ranging sensor array to achieve multi-sensor collaborative detection. This not only comprehensively covers the multi-dimensional detection needs of material surface color and texture, internal composition characteristics, and three-dimensional size and shape, improving the accuracy and coverage of non-conforming material identification, but also ensures detection stability under complex working conditions through stable light supply and dustproof and vibration-proof sensor installation design.

[0030] The CCD camera module and the near-infrared spectral sensor module are respectively housed inside multiple mounting frames 6. Each mounting frame 6 has a transparent glass plate on the side facing the primary guide plate mechanism 3 and the secondary guide plate mechanism 5 to prevent dust mixed in with the material from entering the two modules and affecting the identification module.

[0031] The CCD camera module can accurately capture surface color differences, texture details, and basic shape integrity of materials, quickly distinguishing discolored particles, identifying surface damage, scratches, stains, and other appearance defects, and screening materials with distorted or incomplete shapes. This provides reliable surface visual data support for subsequent sorting. It also forms a multi-dimensional collaborative judgment with other sensors, reducing misjudgments and missed detections associated with single-dimensional detection. The near-infrared spectral sensor module can penetrate and capture internal component and characteristic information of materials, accurately identifying component differences, abnormal moisture content, hidden mold, or mixed-color impurities, thus compensating for the limitations of CCD cameras which can only detect surface features. Overcoming the limitations of conventional methods, this system provides a deeper basis for compositional determination in sorting. In conjunction with other sensors, it enhances sorting accuracy. The laser rangefinder array module can collect real-time information on the three-dimensional dimensions, thickness, distance, and distribution of materials, accurately identifying morphological defects such as excessive particle size, dented shells, and breakage. It also captures the positional shift and movement trajectory of materials during transport, compensating for the deficiencies of CCD camera two-dimensional detection and near-infrared spectral compositional detection in the morphological dimension. This provides accurate spatial position data for subsequent sorting actuators, synergistically improving the targeting and accuracy of sorting. The combined application of these three sensors ensures the detection stability of the system.

[0032] After detecting a non-conforming individual, the corresponding module will send a signal to the execution unit, which will then control the sorting execution structure 9 to perform actions to screen out the non-conforming individual. The sorting execution structure 9 can be a jet valve group composed of multiple jet valves, which blows the non-conforming individual away with high-pressure air.

[0033] Multiple perforated slots 7 are horizontally opened on the outer surfaces of both side uprights 1, which can reduce the overall weight of the device and improve transportation efficiency.

[0034] Furthermore, the screening mechanism 2 includes a horizontally arranged feed frame 21 with open top and bottom. The front and rear surfaces of the feed frame 21 are horizontally perforated with multiple vertically arranged and corresponding through slots 22. The middle of the inner cavity of the feed frame 21 is horizontally rotatably connected to a rotating shaft 23 arranged along its length. Screening strips 24 are horizontally fixedly connected to both sides of the outer surface of the rotating shaft 23. The multiple screening strips 24 on both sides correspond to the multiple through slots 22 on both sides, and the outer ends of the multiple screening strips 24 extend to the outside of the corresponding through slots 22.

[0035] One end of the rotating shaft 23 rotatably passes through one side surface of the feed frame 21 and extends outward. A driven synchronous pulley 25 is fixedly connected to the outer surface of the rotating shaft 23 outside the feed frame 21. A connecting frame 26 is fixedly connected to the lower part of the same side surface of the feed frame 21. A bidirectional motor 27 is fixedly connected to the outer end of the connecting frame 26. A driving synchronous pulley 28 is fixedly connected to the output shaft surface of the bidirectional motor 27. The driving synchronous pulley 28 and the driven synchronous pulley 25 are connected by belt drive.

[0036] Multiple connecting blocks 29 are horizontally fixedly connected to the upper part of both sides of the feed frame 21. The bottom of each connecting block 29 is vertically fixedly connected to a shock-absorbing spring 210. The bottom of each shock-absorbing spring 210 is horizontally fixedly connected to a connecting piece 211. The connecting pieces 211 on both sides are respectively fixedly connected to the inner surface of the two side uprights 1. A vibration motor is provided on the outer surface of the feed frame 21.

[0037] In this embodiment, when the system performs sorting, the material is first poured into the feed frame 21 of the screening mechanism 2. During the material's descent, larger particles are directly filtered out by the two adjacent screening bars 24 and cannot continue to move downwards, thus preventing these larger particles from clogging the subsequent structure. At the same time, the bidirectional motor 27 runs continuously, and its output shaft reciprocates. The active synchronous pulley 28 on the surface of the output shaft drives the driven synchronous pulley 25 to reciprocate synchronously via a belt, causing the rotating shaft 23 to also reciprocate synchronously. During this process, the multiple screening bars 24 on the outer surface of the rotating shaft swing back and forth in both directions, keeping the material that cannot fall on them in a state of continuous movement, preventing the material from accumulating and causing blockage. Meanwhile, the vibrating motor also runs continuously to ensure that the material can flow smoothly downwards.

[0038] The connection structure between the mechanism and the two side supports 1 is equipped with shock-absorbing springs 210 to prevent the vibration of the vibration motor from affecting the side supports 1 and causing damage to the structure below the system.

[0039] Furthermore, the primary guide plate mechanism 3 includes a first plate 31 inclinedly disposed in the middle between the two side uprights 1. The upper part of the front surface of the first plate 31 is fixedly connected to a plurality of first distribution cylinders 32 that are evenly spaced along its length and gradually decrease in size downward in the inner radial direction. The lower part of the front surface of the first plate 31 is vertically fixedly connected to a plurality of diversion channels 33 that correspond to the plurality of first distribution cylinders 32 respectively. The top of the first plate 31 is fixedly connected to a receiving hopper 34 that extends to the bottom opening of the feed frame 21.

[0040] The secondary guide plate mechanism 5 includes a second plate 41 that is inclined between two side uprights 1 and located below and behind the first plate 31 with the same inclination angle. Multiple second distribution cylinders 32 that are evenly spaced along their length and gradually decrease in size in their inner radial direction are fixedly connected to the front surface of the second plate 41. The multiple second distribution cylinders 42 correspond to the multiple first distribution cylinders 42 in position.

[0041] In this embodiment, after the material falls through the screening mechanism 2, it enters the receiving hopper 34 at the top of the primary guide plate mechanism 3, and then enters multiple first distribution cylinders 32. Under its own gravity, it continues to fall. Since the diameter of the first distribution cylinders 32 gradually decreases from top to bottom, the material discharged from its bottom can be more dispersed. Furthermore, with the separation of multiple diversion channels 33, the material will not pile up and fall together, avoiding the material from stacking up and affecting the visual inspection of the material, and further improving the accuracy and coverage of non-conforming material identification.

[0042] After the material falls through the primary guide plate mechanism 2, it will enter the secondary guide plate mechanism 3. The secondary guide plate mechanism 3 is also equipped with multiple secondary distribution cylinders 42 that have the same function as the primary distribution cylinder 32. At the same time, the enlarged opening at the top of the secondary guide plate mechanism 3 can ensure that the material can enter the secondary distribution cylinders 42 stably.

[0043] The working principle and usage process of this invention: After installation, this system integrates a CCD camera module, a near-infrared spectral sensor module, and a laser ranging sensor array. The CCD camera module can accurately capture surface color differences, texture details, and basic shape integrity of materials, quickly distinguishing discolored particles, identifying surface damage, scratches, stains, and other appearance defects, and screening materials with distorted or incomplete shapes. This provides reliable surface visual data support for subsequent sorting and forms a multi-dimensional collaborative judgment with other sensors, reducing misjudgments and missed detections caused by single-dimensional detection. The near-infrared spectral sensor module can penetrate and capture the internal composition and characteristic information of materials, accurately identifying compositional differences, abnormal moisture content, hidden mold, or mixed-color impurities. This overcomes the limitation of the CCD camera, which can only detect surface features, and provides deep compositional information for sorting. The judgment criteria, in conjunction with other sensors, improve sorting accuracy. The laser ranging sensor array module can collect the three-dimensional size, thickness, distance, and distribution information of materials in real time, accurately identify morphological defects such as oversized particles, dented shells, and breakage, and capture the positional deviation and movement trajectory of materials during the conveying process. It makes up for the shortcomings of CCD camera two-dimensional detection and near-infrared spectral component detection in the morphological dimension, and provides accurate spatial position data for subsequent sorting actuators, thus improving the targeting and accuracy of sorting. The combined application of these three sensors realizes multi-sensor collaborative detection, which not only comprehensively covers the multi-dimensional detection needs of material surface color and texture, internal composition characteristics, and three-dimensional size and shape, but also improves the accuracy and coverage of non-conforming material identification. Furthermore, the stable light supply and the dustproof and vibration-proof installation design of the sensors ensure the detection stability under complex working conditions.

[0044] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A multi-sensor fusion intelligent sorting system for color sorters, characterized in that: It includes two vertically arranged and symmetrical side supports (1), a screening mechanism (2), a primary guide plate mechanism (3) and a secondary guide plate mechanism (4); The screening mechanism (2), the primary guide plate mechanism (3), and the secondary guide plate mechanism (4) are arranged sequentially from top to bottom between the two side supports (1). Two fixed horizontal plates (5) are horizontally fixedly connected between the two side supports (1) and on both sides of the separation section between the primary guide plate mechanism (3) and the secondary guide plate mechanism (4). Light strips are horizontally fixedly connected to the inner surfaces of the multiple fixed horizontal plates (5). Two installation frames (6) with open inner ends are horizontally fixedly connected between the two fixed horizontal plates (5) on the same side. CCD camera modules and near-infrared spectral sensor modules are respectively installed inside the two installation frames (6). A horizontal mounting frame (8) is horizontally fixedly connected between the two side supports (1) and at the front of the lower end of the secondary guide plate mechanism (4). A laser ranging sensor array is installed on the rear surface of the horizontal mounting frame (8).

2. The intelligent sorting system for color sorters based on multi-sensor fusion as described in claim 1, characterized in that: The front of the two side brackets (1) is fixedly connected to the device frame (10), the device frame (10) is provided with an execution unit inside, and the front surface of the device frame (10) is provided with a control panel (11).

3. The intelligent sorting system for color sorters based on multi-sensor fusion as described in claim 1, characterized in that: The screening mechanism (2) includes a horizontally arranged feed frame (21) with open top and bottom. The front and rear surfaces of the feed frame (21) are provided with multiple vertically arranged through slots (22) that are respectively corresponding to each other. The middle of the inner cavity of the feed frame (21) is rotatably connected to a rotating shaft (23) arranged along its length. The outer surfaces of the rotating shaft (23) are fixedly connected to screening strips (24) on both sides. The multiple screening strips (24) on both sides correspond to the multiple through slots (22) on both sides. The outer ends of the multiple screening strips (24) extend to the outside of the corresponding through slots (22).

4. The intelligent sorting system for color sorters based on multi-sensor fusion as described in claim 3, characterized in that: One end of the rotating shaft (23) rotatably passes through one side surface of the feed frame (21) and extends outward. A driven synchronous pulley (25) is fixedly connected to the outer surface of the rotating shaft (23) outside the feed frame (21). A connecting frame (26) is fixedly connected to the lower part of the same side surface of the feed frame (21). A bidirectional motor (27) is fixedly connected to the outer end of the connecting frame (26). An active synchronous pulley (28) is fixedly connected to the output shaft surface of the bidirectional motor (27). The active synchronous pulley (28) and the driven synchronous pulley (25) are connected by belt drive.

5. The intelligent sorting system for color sorters based on multi-sensor fusion as described in claim 3, characterized in that: Multiple connecting blocks (29) are horizontally fixedly connected to the upper part of both sides of the feed frame (21). The bottom ends of the multiple connecting blocks (29) are vertically fixedly connected to shock-absorbing springs (210). The bottom ends of the multiple shock-absorbing springs (210) are horizontally fixedly connected to connecting pieces (211). The connecting pieces (211) on both sides are respectively fixedly connected to the inner surfaces of the two side supports (1). A vibration motor is provided on the outer surface of the feed frame (21).

6. The intelligent sorting system for color sorters based on multi-sensor fusion as described in claim 3, characterized in that: The first-level guide plate mechanism (3) includes a first plate (31) inclinedly disposed in the middle between the two side uprights (1). The upper part of the front surface of the first plate (31) is fixedly connected to a plurality of first distribution cylinders (32) evenly spaced along its length and gradually decreasing in size in the inner radial direction. The lower part of the front surface of the first plate (31) is vertically fixedly connected to a plurality of diversion channels (33) corresponding to the plurality of first distribution cylinders (32). The top of the first plate (31) is fixedly connected to a receiving hopper (34) extending to the bottom opening of the feed frame (21).

7. The intelligent sorting system for color sorters based on multi-sensor fusion as described in claim 6, characterized in that: The secondary guide plate mechanism (5) includes a second plate (41) that is inclined between the two side uprights (1) and located below the rear of the first plate (31) with the same inclination angle. A plurality of second distribution cylinders (32) are fixedly connected to the front surface of the second plate (41) and are evenly spaced along its length and gradually decrease in size in the inner radial direction. The plurality of second distribution cylinders (42) correspond to the plurality of first distribution cylinders (42) in position.

8. The intelligent sorting system for color sorters based on multi-sensor fusion as described in claim 7, characterized in that: A sorting execution structure (9) is horizontally fixedly connected between the two side uprights (1) and at the upper and lower parts of the secondary guide plate mechanism (5).

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