Full-automatic intelligent material taking, feeding and packaging integrated equipment and control method thereof

Abstract

The invention discloses full-automatic intelligent material taking, feeding and packaging integrated equipment and a control method thereof, and relates to the technical field of automatic packaging and logistics conveying. The equipment comprises a multi-layer frame, a feeding module, a material arranging module, a boxing module, a material transferring module, a film covering module and a PLC control system. The frame is provided with an electrical layer, at least two conveying layers and a top material arranging layer from bottom to top. The feeding module achieves directional conveying and accurate counting of materials, the material arranging module forms an orderly array through secondary arrangement, the boxing module grabs and boxes in batches through an array suction disc, the material transferring module achieves horizontal conveying and interlayer vertical transferring of material boxes, and the film covering module completes high-quality film covering through tension control, fixed-length traction and accurate cutting. The control system coordinates time sequence operation of all the modules, and full-process automation is achieved. The problems that in the prior art, procedures are dispersed, the automation degree is low, and neatening and film covering precision is poor are solved, and the advantages of being high in integration degree and high in production efficiency and packaging quality are achieved.

Description

Technical Field

[0001] This invention relates to the field of automated packaging and logistics transportation technology, and in particular to a fully automated intelligent conveyor line and its control method that integrates automatic material picking, sorting, boxing, film coating and transfer. Background Technology

[0002] In the production processes of manufacturing industries such as food, electronics, and daily necessities, the handling, sorting, packing, and film packaging of materials are critical steps. In existing technologies, these steps are typically completed by multiple independent machines, requiring manual labor or simple conveyor systems for material transfer between them. This presents the following drawbacks: Low level of automation: The connection between each process relies on manual intervention, which not only increases labor costs, but also easily leads to low production efficiency due to human error. Poor organization accuracy: Material organization relies heavily on manual placement or simple mechanisms for pushing, which makes it difficult to ensure that the materials are arranged neatly, easily leading to chaotic packing and low space utilization. Poor lamination quality: The lack of an effective tension control mechanism during the lamination process makes the packaging film prone to wrinkles, loosening, or excessive stretching and deformation, affecting the sealing performance and aesthetics of the packaging. Inconvenient equipment deployment: Traditional equipment is bulky and has a fixed structure, lacking flexible movement and leveling mechanisms, making it difficult to adapt to different workshop layout requirements; Operation and maintenance are complex: each device is controlled independently, the operation interface is scattered, parameter adjustment is cumbersome, and the equipment has poor sealing. Maintenance requires disassembling a large number of parts, which is time-consuming and labor-intensive. Low integration: The processes of material handling, packing, and film coating are separated, resulting in a lengthy overall production process, a large footprint, and an inability to meet the high-efficiency integration requirements of modern production lines.

[0003] Therefore, there is an urgent need for an integrated, automated, and high-precision conveyor line to solve the aforementioned problems in existing technologies. Summary of the Invention

[0004] This invention provides a fully automatic intelligent integrated material handling and packaging equipment and its control method, aiming to solve the problems of scattered packaging processes, low automation, insufficient production efficiency, poor sorting accuracy, and unstable film quality in the existing technology, and to realize the fully automated integrated operation of material handling, sorting, boxing, filming, and transfer.

[0005] The application is realized by the following technical scheme: a full-automatic intelligent taking, feeding and packaging integrated equipment, comprising a frame, a feeding module, a material arranging module, a boxing module, a material transfer module, a film covering module and a control system; the frame comprises an electrical layer, at least two conveying layers and a material arranging layer at the top from bottom to top, forming a multi-layer three-dimensional layout to optimize the space utilization; the feeding module is arranged on the material arranging layer and is used for directional conveying and accurate counting of scattered materials; the material arranging module is arranged on the material arranging layer and is used for secondary regulation of materials in front and side directions to form a neat array; the boxing module is arranged on the material arranging layer and is used for batch grabbing and accurate placing of the whole batch of materials into a material box; the material transfer module is arranged on the conveying layer and is used for horizontal conveying and vertical transfer of the material box between layers; the film covering module is arranged between the conveying layer and the material arranging layer and is used for automatic film covering of the boxed materials; and the control system coordinates the timing operation of each module to realize full-process automatic operation.

[0006] Further, the frame periphery is formed into a closed or semi-closed shell by a sealing plate to play a role of safety protection, dust prevention and noise reduction, and to make the appearance neat. A door plate and an integrated interactive panel are arranged on the front of the frame, the door plate is convenient for internal mechanism maintenance, and the interactive panel provides a man-machine interface for centralized monitoring and parameter setting of the operator to improve operation intuitiveness and convenience. The frame bottom is configured with a roller and an adjustable supporting leg, the roller is used for easy displacement during movement, and the height of the supporting leg is adjusted to realize stable support and horizontal leveling after positioning, thereby enhancing equipment deployment flexibility. The electrical box is fixedly arranged in the electrical layer to centrally integrate electrical control elements, so that wiring is neat and signal interference is reduced; the material arranging layer is pre-provided with horizontal guide rails to provide a modular and slidable installation base for external operation mechanism, thereby facilitating quick installation and replacement of functional modules according to process requirements, and improving process adaptability and expandability.

[0007] Further, the feeding module comprises a transmission belt driven by a feeding motor, adjustable spacing limiting plates symmetrically arranged on both sides of the transmission belt, an adjusting piece for adjusting the spacing of the limiting plates, and a sensor arranged at the output end of the transmission belt. The surface of the transmission belt is designed with anti-skid to prevent material conveying deviation; the spacing of the limiting plates on both sides is adjusted to adapt to materials of different width specifications, thereby improving equipment flexibility. The sensor comprises a material presence / absence detection sensor and a position positioning sensor, which are respectively used for detecting the number of material accumulation and the accurate position, feeding signals to the control system in real time, triggering subsequent material arranging actions when reaching a preset threshold, realizing directional, orderly conveying and accurate counting of materials, and providing a reliable premise for batch arrangement.

[0008] Further, the whole material module comprises a front pushing mechanism, a material moving mechanism, a side straightening mechanism mounted on the material moving mechanism, and a blocking mechanism suspended in front of the front pushing mechanism; the material moving mechanism is provided with a material carrying plate with lateral and longitudinal surrounding plates, and the surrounding plates cooperate with the side straightening mechanism to form a circumferential limit for the material. During operation, the blocking mechanism first blocks the accumulated material to realize front alignment and complete the first straightening; the front pushing mechanism then pushes the quantified material into the material carrying plate, and the process is repeated until the material in the material carrying plate reaches the preset batch size, and then the side straightening mechanism pushes and straightens the side edges of the material to complete the second straightening. The front pushing plate of the front pushing mechanism and the straightening pushing plate of the side straightening mechanism are connected through guide columns and buffers, so that the pushing process is stable and soft, reducing the impact damage to the material, and at the same time ensuring that the material forms a neat rectangular array, laying a high-precision foundation for mechanized grabbing and boxing.

[0009] Further, the boxing module comprises a suction disc provided with an array of suction nozzles, a gantry, and a suction disc lifting mechanism. The suction disc lifting mechanism adopts gear and rack transmission, and is driven by a suction disc lifting motor to lift the lifting plate along the suction disc lifting guide rail accurately; the suction disc is fixed to the bottom of the lifting plate, and the layout of the suction nozzles matches the material array. When the whole batch of materials is moved to the boxing station, the suction disc is lowered and all the materials are sucked by negative pressure at the same time, and then accurately placed into the lower material box, realizing fast, damage-free and accurate transfer of the whole batch of materials, greatly improving the boxing efficiency and reliability.

[0010] Further, the material transfer module comprises a material box entering mechanism, a material box output mechanism, and a material box lifting mechanism with the same structure. The material box entering mechanism and the material box output mechanism both adopt a plurality of transfer rollers and a transfer motor driving the rollers to realize low-friction horizontal conveying of the material box; the material box lifting mechanism adopts a "screw-nut" sub-drive, which is driven by a lifting motor to rotate the screw rod, driving the tray to make precise vertical motion along the material box lifting guide rail. The tray is provided with a tray roller driven by a material box lifting roller motor, which can realize seamless connection between horizontal conveying and vertical lifting of the material box, constitute the core circulation of the internal logistics of the equipment, and ensure smooth and efficient circulation of the material box in the multi-layer space.

[0011] Further, the film covering module comprises a film releasing mechanism, a film pulling mechanism, a film pressing mechanism, a cutting mechanism and a pressing table. The film releasing mechanism comprises a film releasing roller and a tension adjusting roller located between the film releasing roller and the guide cylinder, for adjusting the transmission tension of the packaging film to ensure the film surface is flat, avoiding slack or excessive tightness; the film pulling mechanism comprises a film grabbing clamp and a film pulling moving mechanism for driving the film grabbing clamp to move, the upper clamp piece and the lower clamp piece of the film grabbing clamp are provided with sawtooth anti-skid lines on the opposite engaging surfaces, which enhances the clamping stability and prevents the film material from falling off and slipping; the film pressing mechanism comprises two groups of independent pressing rollers located on both sides of the cutting seam of the pressing table, which can press the film material tightly before and after cutting to avoid displacement of the film material; the surface of the pressing table and the outer surface of the pressing rollers are provided with anti-skid rubber layers, which further improve the stability of the film material conveying and pressing process, and the pressing table is also provided with a cutting seam for the knife blade to pass through and an engaging gap for the film grabbing clamp to extend into, which is suitable for cutting and film clamping actions; the cutting mechanism is driven by a cutting cylinder, and the knife blade accurately passes through the cutting seam to complete the fixed-length cutting of the packaging film, ensuring the accuracy of the film covering size.

[0012] Further, the control system is a PLC controller connected with the interactive panel, various sensors, all driving motors and execution cylinders. The PLC controller serves as the control center, receives various sensor feedback signals in real time, and according to the preset logic program, orderly coordinates the execution time sequence and action parameters of all processes such as feed counting, material regularizing, material grabbing and boxing, material box circulation, film covering and packaging, to realize the unmanned and intelligent collaborative control of the whole equipment from feeding to finished product output.

[0013] Further, the application also provides a control method for the above-mentioned full-automatic intelligent material taking and packaging integrated equipment, which comprises the following core steps: S1, empty box input and lifting: after the equipment is initialized, the empty material box is input through the box input mechanism and lifted to the material layer by the box lifting mechanism; S2, material feeding and counting: the feeding module is started, the materials are sequentially and directionally conveyed, the sensors count in real time, and the process is paused when the preset number (3-10) is reached; S3, batch regularizing and arraying: the material regularizing module is started, the fixed amount of materials is pushed into the loading plate and aligned at the front end by the front pushing mechanism and the blocking mechanism, and the process is repeated until the total amount of materials in the loading plate reaches the preset batch amount (30-50), then the side regularizing mechanism is used to regularize the side edges to form a neat array; S4, batch grabbing and boxing: the material moving mechanism moves the regularized batch of materials to the boxing station, and the suction cup of the boxing module is lowered to grab the materials and accurately put them into the material box; S5, automatic film covering and packaging: the film covering module is started to sequentially complete the film pulling, fixed-length pulling, film pressing, cutting and film covering operations to ensure that the packaging film covers the materials flatly; S6, product output: the material box after film coating is lowered to the conveying layer by the material box lifting mechanism, and is output by the material box output mechanism.

[0014] In the control method, key process parameters (single pushing material quantity, total material batch quantity, film coating traction length, etc.) can be flexibly set through the interactive panel, so that the equipment has good flexibility and can adapt to the packaging needs of materials of different sizes and specifications.

[0015] Compared with the prior art, the present application has the following advantages: High integration and full automation: multiple processes such as material taking, material arranging, boxing, film coating and transfer are integrated in one device, and full-process automation is realized through an intelligent control system, significantly reducing manual intervention and improving production efficiency and operation consistency. High precision and high quality: through the double-arranging mechanism of "blocking initial arrangement + lateral secondary arrangement", precise lifting of the lead screw and array-type suction cup grabbing, the material arrangement is ensured to be neat and the boxing is precise; the film coating module avoids wrinkles and displacement of the film material through tension control, anti-slip design and fixed-length cutting, ensures the flatness and sealing beauty of the packaging film, and improves the packaging quality. Flexibility and ease of use: the spacing between the feeding modules is adjustable, and the key process parameters can be set to adapt to the packaging of materials of different sizes and specifications; the device is equipped with mobile rollers, adjustable feet and integrated human-machine interface, is flexible to deploy and easy to operate and maintain. Compact structure and high reliability: a multi-layer frame design is adopted to optimize the space utilization rate and adapt to compact production layout; the module mechanisms are mature and reliable, the electrical components are arranged centrally, and the control system is stable, which ensures the stability and maintenance convenience of long-term operation of the equipment. Good material protection: the front pushing mechanism and the side arranging mechanism are provided with bumpers to reduce the impact of the pushing plate on the material and reduce the risk of surface damage to the material. BRIEF DESCRIPTION OF DRAWINGS

[0016] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0017] Figure 1 The overall schematic diagram provided for the embodiments of the present application; Figure 2 The overall structure schematic diagram provided for the embodiments of the present application; Figure 3 The explosion schematic diagram provided for the embodiments of the present application; Figure 4The feeding module structure schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 5 、 6 The monolith module structure schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 7 The monolith module explosion schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 8 The front pushing mechanism explosion schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 9 The side straightening mechanism and material moving mechanism explosion schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 10 The side straightening mechanism and material moving mechanism structure schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 11 The blocking mechanism structure schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 12 、 13 The boxing module structure schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 14 The material box entering mechanism and material box output mechanism schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 15 The material box lifting mechanism schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 16 The film covering module schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 17 The film covering module explosion diagram provided by the embodiment of the present application is shown in the figure; Figure 18 The film covering module structure schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 19 The cutting mechanism structure schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 20 、 21 The film pressing mechanism and pressing table structure schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 22 The film pulling moving mechanism structure schematic diagram provided by the embodiment of the present application is shown in the figure; Figure 23 The film pulling schematic diagram provided by the embodiment of the present application is shown in the figure.

[0018] In the figure, various reference signs are as follows: 1, frame; 11, sealing plate; 12, door plate; 13, interactive panel; 14, electrical layer; 15, first conveying layer; 16, second conveying layer; 17, monolith layer; 18, electrical box; 2, feeding module; 21, feeding motor; 22, transmission belt; 23, limiting plate; 24, adjusting piece; 3, whole material module; 31, front pushing mechanism; 311, front pushing motor; 312, front pushing mounting frame; 313, front pushing guide rail; 314, front pushing belt; 315, front pushing frame; 316, front pushing plate; 317, front pushing slider; 32, side shaping mechanism; 321, shaping motor; 322, shaping guide rail; 323, shaping guide column; 324, buffer; 325, shaping push plate; 326, shaping push plate frame; 33, material moving mechanism; 331, material moving cylinder; 332, material moving connecting plate; 333, material carrying plate; 3331, surrounding plate; 34, blocking mechanism; 341, blocking baffle; 342, blocking cylinder; 343, blocking cylinder mounting plate; 35, whole material bottom plate; 4, boxing module; 41, suction cup; 42, gantry; 43, suction cup lifting mechanism; 431, suction cup lifting motor; 432, suction cup lifting guide rail; 433, rack; 434, lifting plate; 5, material transfer module; 51, material box entering mechanism; 511, transfer roller; 512, transfer motor 52, material box lifting mechanism; 521, tray; 522, tray roller; 523, screw rod; 524, material box lifting guide rail; 525, material box lifting roller motor; 53, material box output mechanism; 6, film covering module; 61, cutting mechanism; 611, cutting cylinder; 612, blade; 613, cutting cylinder piston; 62, film pulling mechanism; 621, film pulling moving mechanism; 6211, film pulling motor; 6212, film pulling belt; 6213, film pulling mounting seat; 6214, film pulling guide rail; 622, film grabbing clamp hand; 6221, film clamping cylinder; 6222, lower clamping piece; 6223, upper clamping piece; 63, film pressing mechanism; 631, first pressing cylinder; 632, first pressing roller; 633, second pressing cylinder; 634, second pressing roller; 64, film placing mechanism; 65, pressing table; 651, guide roller; 652, cutting seam; 653, occlusion notch; 7, material; 71, material box; 72, sensor; 73, packaging film.

[0019] Through the above drawings, the specific embodiments of the present application have been shown, and will be described in more detail hereinafter. These drawings and textual descriptions are not intended to limit the scope of the concept of the present application in any way, but to illustrate the concept of the present application to those skilled in the art by referring to specific embodiments. DETAILED DESCRIPTION

[0020] With reference to the drawings of the embodiments of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments of the present application, all the other embodiments obtained by a person of ordinary skill in the art without creative work belong to the scope of protection of the present application.

[0021] In order to make the technical solutions and advantages of the present application clearer, the embodiments of the present application will be further described in detail below with reference to the drawings.

[0022] As shown in FIGS. 1-23, the present application provides a full-automatic intelligent material taking, packaging integrated equipment, the core of which is to seamlessly integrate the originally dispersed material taking, regularizing, boxing, film covering and material flow processes through modular design and centralized intelligent control, forming a continuous and efficient automatic operation system.

[0023] The basis of the equipment is a multi-layer frame 1, which includes, from bottom to top, an electrical layer 14, a first conveying layer 15, a second conveying layer 16 and a material regularizing layer 17. This layered layout makes full use of the vertical space to realize the three-dimensional flow of materials. The main body of the frame 1 is welded from aluminum profiles or steel structures to ensure overall rigidity and carrying capacity. The periphery of the frame 1 is enclosed or semi-enclosed by an enclosure plate 11 to form a protective enclosure for safety protection, dust prevention and noise reduction, and to make the appearance of the equipment more tidy. The front of the frame 1 is provided with a hinged door plate 12 for easy daily maintenance and repair of the internal mechanism. The door plate 12 is embedded with an integrated interactive panel 13, usually an industrial touch screen, which constitutes the human-machine interface of the equipment for state monitoring, parameter setting and manual operation, greatly improving the convenience of human-machine interaction. The frame 1 is installed with a combination of rollers and adjustable feet at the four corners, so that the equipment can be easily moved to adapt to different work station layouts, and after being placed in position, the adjustable feet can be adjusted to achieve stable support and horizontal leveling, enhancing the site adaptability. The electrical layer 14 is fixedly placed with an electrical box 18, which integrates PLC controllers, power modules, drivers and other electrical control components. The strong and weak electrical wiring is regular, reducing signal interference and facilitating installation and maintenance. The material regularizing layer 17 is pre-installed with horizontal guide rails to provide a modular installation base for the operation mechanism, allowing quick replacement of functional modules and improving process adaptability.

[0024] In actual use, the equipment first completes initialization. Empty material boxes 71 enter from the entrance of the first conveying layer 15 and are received by the box entry mechanism 51 of that layer. The box entry mechanism 51 consists of a set of parallel transfer rollers 511. The transfer motor 512 drives all transfer rollers 511 to rotate synchronously via a chain or belt, horizontally conveying the empty material boxes 71 to the handover station aligned with the box lifting mechanism 52. At the same time, the tray 521 of the box lifting mechanism 52, driven by the lead screw 523, rises along the box lifting guide rail 524 to a height level with the first conveying layer 15. The tray rollers 522 on the tray 521 are driven to rotate by the box lifting roller motor 525, smoothly picking up the empty material boxes 71 from the transfer rollers 511 onto the surface of the tray 521. Then, the box lifting mechanism 52 drives the tray 521 to rise to the full material layer 17, waiting for the material to be boxed.

[0025] like Figure 4 , 5 As shown in Figure 6, the feeding process starts simultaneously with the preparation of the material bins. The feeding module 2 is installed at the front end of the material layer 17, and its feeding motor 21 is connected to the pulley of the conveyor belt 22 through a coupling, driving the conveyor belt 22 to rotate at a uniform speed. An external feeding robot places individual materials 7 sequentially on the left end of the conveyor belt 22. The surface of the conveyor belt 22 is made of anti-slip rubber, and a pair of limiting plates 23 are symmetrically installed on both sides. The distance between the two plates can be steplessly adjusted by the adjusting component 24. In this embodiment, it is adjusted to 10 cm to ensure that the materials 7 will not shift or tip over during the conveying process. Guided by the limiting plates 23, the materials 7 move to the right end with the conveyor belt 22. A sensor 72 is installed at the output end of the conveyor belt 22. The sensor 72 includes a material presence detection sensor and a position positioning sensor, which detects and counts the quantity and precise position of the materials accumulated here in real time. When sensor 72 detects that the number of materials piled up has reached a preset value (e.g., 5), it immediately sends a signal to the PLC controller. The PLC controller then issues an instruction to stop the feeding motor 21 and pause the conveyor belt 22, thus completing the preparation of a batch of materials.

[0026] Next, the whole material module 3 starts to work, and the 5 materials are regularized. The mechanical basis of the whole material module 3 is the whole material base plate 35, on which the guide rail and support are fixedly installed, and the front pushing mechanism 31 and the material moving mechanism 33 are fixed on the whole material base plate 35 by bolts. The front pushing mechanism 31 includes a front pushing mounting frame 312, a front pushing motor 311, a front pushing guide rail 313, a front pushing belt 314, a front pushing frame 315, a front pushing plate 316 and a front pushing sliding block 317. The front pushing mounting frame 312 is fixed with the whole material base plate 35, the front pushing motor 311, the front pushing guide rail 313 and the front pushing belt 314 are installed on the front pushing mounting frame 312, the front pushing frame 315 is slidably connected with the front pushing guide rail 313 through the front pushing sliding block 317, the front pushing plate 316 is connected with the front pushing frame 315 through guide columns, and the front pushing motor 311 drives the front pushing frame 315 and the front pushing plate 316 to move back and forth along the front pushing guide rail 313 through the front pushing belt 314. The blocking mechanism 34 is suspendedly installed in front of the front pushing mechanism 31 and directly in front of the entrance of the material carrying plate 333 through a blocking cylinder mounting plate 343, the blocking cylinder 342 is fixed on the blocking cylinder mounting plate 343, and the top end of the piston rod is fixedly connected with the blocking baffle 341. The material moving mechanism 33 includes a material moving cylinder 331, a material moving connecting plate 332 and a material carrying plate 333. The cylinder body of the material moving cylinder 331 is fixed on the whole material base plate 35, the piston rod is rigidly connected with the material carrying plate 333 through the material moving connecting plate 332, and the material carrying plate 333 is provided with lateral and longitudinal surrounding plates 3331 to form circumferential limiting of the materials in cooperation with the side straightening mechanism 32. The side straightening mechanism 32 is installed on the material moving connecting plate 332 and includes a straightening motor 321, a straightening guide rail 322, a straightening guide column 323, a buffer 324, a straightening pushing plate 325 and a straightening pushing plate frame 326. The straightening motor 321 and the straightening guide rail 322 are fixedly installed on the straightening pushing plate frame 326, the straightening pushing plate frame 326 is slidably connected with the straightening guide rail 322 through a sliding block, the straightening pushing plate 325 is connected with the straightening pushing plate frame 326 through the straightening guide column 323 and the buffer 324, and the buffer 324 is a spring buffer which can effectively reduce the pushing impact.

[0027] The regularizing process is divided into two steps, first, "front-end alignment": the PLC controller controls the blocking cylinder 342 of the blocking mechanism 34 to act, driving the blocking baffle 341 to extend downward to the blocking position; at the same time, control the front pushing mechanism 31 to start, the front pushing motor 311 drives the front pushing frame 315 and the front pushing plate 316 to move forward along the front pushing guide rail 313 through the front pushing belt 314, pushing the accumulated 5 materials 7 forward to the direction of the loading plate 333. The front end of the material 7 first resists the falling blocking baffle 341, and under the blocking action of the blocking baffle 341, the rear end of the 5 materials 7 is aligned, completing the initial regularizing. Subsequently, the blocking cylinder 342 retracts the blocking baffle 341, and the front pushing mechanism 31 continues to advance, smoothly pushing the batch of front-end aligned materials 7 into the loading plate 333, and the surrounding plate 3331 on the loading plate 333 forms a preliminary lateral and longitudinal limit on the material 7. After the pushing is completed, the front pushing mechanism 31 is reset under the control of the PLC controller, and the blocking baffle 341 of the blocking mechanism 34 is also reset to the downward extension state, and the PLC controller controls the feeding motor 21 to restart, and the conveying belt 22 resumes material conveying, entering the accumulation counting process of the next batch of materials.

[0028] When the above-mentioned "feeding-counting-front pushing regularizing" cycle is repeated for a predetermined number of times (for example, 8 times), 40 materials 7 have been loaded into the loading plate 333. At this time, the PLC controller starts the secondary regularizing program: control the regularizing motor 321 of the side regularizing mechanism 32 to act, drive the regularizing push plate frame 326 to move along the regularizing guide rail 322 to one side of the material array through the screw, and the regularizing push plate 325 gradually contacts the side of the material 7 under the buffering action of the buffer 324. With the continuous movement of the regularizing push plate frame 326, the regularizing push plate 325 uniformly pushes the side of the 40 materials 7, forcing all the sides of the materials 7 to align, achieving secondary regularizing and ensuring that the materials 7 in the loading plate 333 are arranged in a regular rectangular array. After the secondary regularizing is completed, the regularizing mechanism 2 is reset, the piston rod of the material moving cylinder 331 of the material moving mechanism 33 is extended, driving the loading plate 333 to move horizontally along the guide rail on the material loading plate 35 through the material moving connecting plate 332, until the loading plate 333 reaches the pre-set grabbing position below the boxing module 4.

[0029] After the material is sorted, it enters the boxing process. The boxing module 4 includes a gantry 42, a suction cup 41, and a suction cup lifting mechanism 43. The gantry 42 spans above the through hole specially designed on the material bottom plate 35, and the suction cup lifting mechanism 43 is installed on the crossbeam of the gantry 42. The suction cup lifting mechanism 43 includes a suction cup lifting motor 431, a suction cup lifting guide rail 432, a rack 433, and a lifting plate 434. The suction cup lifting guide rail 432 is vertically fixed on the gantry 42, the lifting plate 434 is slidably connected with the suction cup lifting guide rail 432 through a sliding block, the lifting plate 434 is provided with the rack 433 which is engaged with the gear of the suction cup lifting motor 431, and the suction cup 41 is fixed on the bottom of the lifting plate 434 through a mounting plate. The suction surface of the suction cup 41 is composed of a plurality of arrayed small suction nozzles, and the layout is matched with the material array. When the material loading plate 333 is in place, the suction cup lifting motor 431 is started to drive the gear to rotate, and the lifting plate 434 is driven to descend along the suction cup lifting guide rail 432 through the engagement with the rack 433. After the suction cup 41 contacts the top of the material 7, the vacuum generator works, and all the suction nozzles generate negative pressure to firmly suck the whole batch of 40 materials 7. Then, the suction cup lifting mechanism 43 drives the lifting plate 434 to rise to lift the whole batch of materials 7, and the material moving mechanism 33 drives the empty material loading plate 333 to retreat to the initial position to prepare for the next round of sorting. Then, the suction cup lifting mechanism 43 drives the lifting plate 434 to descend again, passes through the through hole of the material bottom plate 35, and accurately places the sucked whole batch of materials 7 into the material box 71 waiting on the tray 521 of the material box lifting mechanism 52, to complete the high-speed and lossless whole batch boxing operation.

[0030] After the material is packed, the film covering and packaging process is started. The film covering module 6 is installed between the whole material layer 17 and the second conveying layer 16, mainly including a film releasing mechanism 64, a film pulling mechanism 62, a film pressing mechanism 63, a cutting mechanism 61 and a pressing table 65. The film releasing mechanism 64 is located at the bottom layer of the equipment, and the film releasing roller loaded with the roll-shaped packaging film 73 releases the film material under the control of a damper or a motor. After the packaging film 73 is drawn out, it passes through a tension adjusting roller, and the conveying tension can be adjusted by manual counterweight or automatic sensing mode to ensure that the film surface is flat and wrinkle-free. Then the film material changes the path through the guide roller 651 on the pressing table 65, and finally is laid on the working surface of the pressing table 65. The film pulling mechanism 62 includes a film pulling motor 6211, a film pulling belt 6212, a film pulling mounting seat 6213, a film pulling guide rail 6214 and a film grabbing clamp 622. The film pulling mounting seat 6213 is fixed on the support, the film pulling motor 6211, the film pulling guide rail 6214 and the film pulling belt 6212 are installed on the film pulling mounting seat 6213, the film grabbing clamp 622 is slidably connected with the film pulling guide rail 6214 through the sliding block, the film grabbing clamp 622 includes a film clamping cylinder 6221, a lower clamping piece 6222 and an upper clamping piece 6223, the lower clamping piece 6222 is fixed, and the upper clamping piece 6223 is driven by the film clamping cylinder 6221 and can be opened and closed relative to the lower clamping piece 6222. The film pressing mechanism 63 includes a first lower pressing cylinder 631, a first pressing roller 632, a second lower pressing cylinder 633 and a second pressing roller 634. The first lower pressing cylinder 631 and the second lower pressing cylinder 633 are respectively installed on the two sides of the pressing table 65, and the first pressing roller 632 and the second pressing roller 634 are respectively fixed on the top end of the piston rod of the first lower pressing cylinder 631 and the second lower pressing cylinder 633. The cutting mechanism 61 includes a cutting cylinder 611, a cutting cylinder piston 613 and a blade 612. The cutting cylinder 611 is fixed below the pressing table 65, the blade 612 is connected with the cutting cylinder 611 through the cutting cylinder piston 613, the pressing table 65 is provided with a cutting slot 652 corresponding to the blade 612, one end of the cutting slot 652 is provided with a clamping notch 653 for the film grabbing clamp 622 to extend into and clamp the packaging film 73.

[0031] The film covering process is automatically carried out in the following steps: initial film pressing and clamping stage, the second lower pressing cylinder 633 in the film pressing mechanism 63 close to the film feeding direction is actuated, the second pressing roller 634 is driven to press down, the front end region of the packaging film 73 is pressed on the surface of the pressing table 65, the surface of the pressing table 65 is covered with an anti-skid rubber layer, which further increases the friction with the packaging film 73 and prevents the film material from shifting. Subsequently, the film pulling motor 6211 of the film pulling moving mechanism 621 is started, the film pulling belt 6212 drives the film clamping gripper 622 to move along the film pulling guide rail 6214 towards the engagement gap 653 of the pressing table 65, and when the film clamping gripper 622 moves to the position directly above the engagement gap 653, it is stopped, the film clamping cylinder 6221 drives the upper clamping piece 6223 to move downward and engage with the lower clamping piece 6222. Since the upper clamping piece 6223 and the lower clamping piece 6222 are provided with sawtooth anti-skid lines of silicone material on the opposite engagement surfaces, the clamping force on the end of the packaging film 73 can be effectively enhanced to prevent the film material from falling off or slipping during clamping. After the film clamping gripper 622 stably clamps the packaging film 73, the second lower pressing cylinder 633 drives the second pressing roller 634 to lift upward, releasing the pressing of the front end of the packaging film 73 to release space for subsequent traction action.

[0032] During the fixed-length transfer process, the film pulling motor 6211 is started again, the film pulling belt 6212 drives the film clamping gripper 622 to move along the film pulling guide rail 6214 towards the material box 71, thereby pulling the packaging film 73 to smoothly expand. The anti-skid rubber layer on the outer periphery of the guide roller 651 plays a role of auxiliary guide and anti-skid block in this process, avoiding the deviation of the packaging film 73 during traction. The position sensor of the film pulling moving mechanism 621 detects the moving position of the film clamping gripper 622 in real time and continuously feeds back signals to the control system. When it is detected that the film clamping gripper 622 has moved to the preset position directly above the material box 71, the control system issues a stop command and the film pulling motor 6211 stops working, thereby realizing accurate control of the pulling length of the packaging film 73 and ensuring that the subsequent film covering can completely cover the products in the material box 71.

[0033] The film pressing and cutting stage is started immediately, the first down cylinder 631 and the second down cylinder 633 of the film pressing mechanism 63 act simultaneously, respectively driving the first pressing roller 632 and the second pressing roller 634 to press down synchronously, tightly pressing the packaging film 73 that has been pulled and unfolded on the pressing table 65, at this time, the cutting position of the packaging film 73 is just above the cutting slot 652 of the pressing table 65, and the anti-skid rubber layer of the outer circumferential surface of the first pressing roller 632 and the second pressing roller 634 further improves the stability of the pressing, preventing the packaging film 73 from wrinkling or shifting during cutting. Subsequently, the cutting cylinder 611 of the cutting mechanism 61 drives the cutting cylinder piston 613 to move, driving the blade 612 to accurately pass through the cutting slot 652 to quickly cut the packaging film 73, after cutting, the cutting cylinder 611 drives the cutting cylinder piston 613 and the blade 612 to reset, waiting for the next cutting instruction.

[0034] The film covering into the box stage, after cutting, the first pressing roller 632 close to the material box 71 side is lifted first under the drive of the first down cylinder 631, loosening the end of the packaging film 73 on this side. Subsequently, the film pulling motor 6211 of the film pulling mechanism 62 drives the film grabbing clamp 622 to move a small distance towards the material box 71 again, so that the front end of the packaging film 73 that has been loosened naturally falls under the action of gravity and accurately falls into the material box 71. Then, the clamping cylinder 6221 drives the upper clamping piece 6223 to lift upwards, loosening the rear end of the packaging film 73, and the whole packaging film 73 covers the products in the material box 71 evenly, completing an automatic film covering and boxing operation. After the operation is completed, the film pulling mechanism 62 resets, and the second pressing roller 634 presses the front end of the new packaging film 73 again, entering the next operation cycle.

[0035] After the film covering is completed, the tray 521 is lowered by the material box lifting mechanism 52, and the material box 71 that has completed packaging is delivered to the second conveying layer 16. The material box output mechanism 53 of this layer is started, which has the same structure as the material box entering mechanism 51. The transfer roller 511 rotates under the drive of the transfer motor 512, horizontally conveying the finished box out of the equipment, marking the end of this operation cycle. The system enters the next cycle immediately, realizing continuous and uninterrupted automatic production.

[0036] In this embodiment, PLC (Programmable Logic Controller) is used as the control center. The PLC controller is connected with the interactive panel 13, sensors 72 at various positions, all drive motors (such as the feeding motor 21, the transfer motor 512, the front pushing motor 311, the sizing motor 321, the suction cup lifting motor 431, the film pulling motor 6211, etc.) and the electromagnetic valve signals of various execution cylinders (such as the material moving cylinder 331, the blocking cylinder 342, the first downward pressing cylinder 631, the second downward pressing cylinder 633, the cutting cylinder 611, the film clamping cylinder 6221, etc.) through industrial bus or I / O module. The PLC has a well-written control program stored therein. It continuously receives real-time feedback signals (such as counting signals, in-place signals) from the sensors, and sends precise control instructions to each execution component according to the preset logic and timing, so as to coordinate the orderly, cooperative and efficient work of the five modules of feeding, sizing, boxing, transferring and film covering, and realize highly automated and intelligent control of the whole process from empty box input to finished product output.

[0037] It should be noted that the driving mode of part of the mechanism in this embodiment can be replaced according to production needs. For example, the sizing motor 321 can be replaced by a cylinder, and the material moving cylinder 331 can be replaced by a lead screw mechanism or a linear motor, as long as the power output is stable and meets the requirements of stroke and accuracy. In addition to spring buffers, the buffer 324 can also be selected as a hydraulic buffer to adapt to the buffering needs of different materials. When it is necessary to adapt to materials of different sizes, the distance between the limiting plates 23 can be adjusted by the adjusting piece 24, and the parameters such as the number of material accumulation and the total feeding quantity of the carrier plate can be reset by the PLC controller, without the need for substantial modification of the mechanism, and the adaptability is strong. During the operation of the equipment, if the sensor 72 has sensing abnormalities, the mechanism action is stuck or the material sizing is unqualified, etc., the PLC controller will immediately control the equipment to stop, and send out sound and light alarm through the alarm device, reminding the operator to check and handle, and ensuring the safety of equipment operation.

[0038] In summary, the present application combines innovative mechanical structure design and intelligent control logic to build a highly integrated, smooth running and flexible adjustment full-automatic packaging production line, effectively solves the problems of multi-process connection, high dependence on manual operation, inconsistent packaging quality and other industry pain points, and has significant practical value and promotion prospect.

[0039] Other embodiments of the application will be apparent to those skilled in the art from consideration of the specification and practice of the application. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the application being indicated by the following claims.

[0040] It should be noted that when an element or layer is referred to as being "on" another element or substrate, it can be directly on the other element or substrate, or intervening elements can also be present. In contrast, when an element is referred to as being "directly on" another element or substrate, there are no intervening elements present. Like numbers refer to like elements throughout. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0041] It is to be understood that the application is not limited to the precise construction described in the specification and as shown in the attached drawings, and that various modifications and changes can be effected therein by those skilled in the art without departing from the scope of the application. The scope of the application is to be limited only by the appended claims.

Claims

1. A fully automatic intelligent integrated material feeding and packaging equipment, characterized in that, include: The frame (1) includes, from bottom to top, an electrical layer (14), at least two conveying layers and a top material layer (17). The feeding module (2), located on the material layer (17), is used to directionally convey and count the scattered materials (7); The material preparation module (3) is located on the material preparation layer (17) and is used to prepare the material (7) to form a neat array; The packing module (4) is located on the material layer (17) and is used to grab the entire batch of materials (7) and put them into the material box (71). The material transfer module (5) is located on the conveying layer and is used for horizontal conveying and vertical transfer between layers of the material box (71). A film coating module (6) is located between the conveying layer and the material preparation layer (17) and is used to automatically coat the packaged materials. The control system is electrically connected to each module and is used to coordinate the sequential operation of each module.

2. The fully automatic intelligent integrated material feeding and packaging equipment according to claim 1, characterized in that: The frame (1) is surrounded by a sealing plate (11), an openable door panel (12) and an integrated interactive panel (13). The bottom is equipped with rollers and adjustable feet. An electrical box (18) is fixedly placed inside the electrical layer (14). A horizontal guide rail is preset inside the material layer (17) for the installation of external operating mechanisms.

3. The fully automatic intelligent integrated material feeding and packaging equipment according to claim 1, characterized in that: The feeding module (2) includes a feeding motor (21), a conveyor belt (22) driven by the feeding motor (21), a limiting plate (23) symmetrically arranged on both sides of the conveyor belt (22), an adjusting member (24) for adjusting the spacing of the limiting plate (23), and a sensor (72) located at the output end of the conveyor belt (22); the sensor (72) includes a material presence detection sensor and a position positioning sensor, used to detect the quantity and position of the material (7) accumulation.

4. The fully automatic intelligent integrated material feeding and packaging equipment according to claim 1, characterized in that: The material preparation module (3) includes a material preparation base plate (35), a front pushing mechanism (31) and a material transfer mechanism (33) installed on the material preparation base plate (35), a side aligning mechanism (32) installed on the material transfer mechanism (33), and a blocking mechanism (34) suspended in front of the front pushing mechanism (31). The material transfer mechanism (33) is provided with a material carrier plate (333) with a side enclosure and a longitudinal enclosure. The front pushing plate (316) of the front pushing mechanism (31) and the aligning pushing plate (325) of the side aligning mechanism (32) are both connected to the buffer (324) through guide posts (323). The blocking mechanism (34) is used to align the front end of the material (7). The side aligning mechanism (32) is used to push and align the material (7) in the material carrier plate (333) from the side.

5. The fully automatic intelligent integrated material feeding and packaging equipment according to claim 1, characterized in that: The packing module (4) includes a suction cup (41), a gantry frame (42), and a suction cup lifting mechanism (43). The suction cup (41) is provided with an array of suction nozzles and is fixed to the bottom of the suction cup lifting mechanism (43). The suction cup lifting mechanism (43) includes a suction cup lifting motor (431), a gear, a suction cup lifting guide rail (432), a rack (433), and a lifting plate (434) with a rack (433). The suction cup lifting motor (431) drives the gear to rotate and drives the rack (433), thereby moving the lifting plate (434) along the suction cup lifting guide rail (432).

6. The fully automatic intelligent integrated material feeding and packaging equipment according to claim 1, characterized in that: The material transfer module (5) includes a hopper inlet mechanism (51) and a hopper outlet mechanism (53) with the same structure, as well as a hopper lifting mechanism (52). The hopper inlet mechanism (51) and the hopper outlet mechanism (53) each include a number of transfer rollers (511) and a transfer motor (512) that drives the transfer rollers (511). The hopper lifting mechanism (52) includes a lead screw (523) driven by a lifting motor and a tray (521) that moves along the hopper lifting guide rail (524). The lead screw (523) rotates to drive the tray (521) to lift. The tray (521) is provided with a tray roller (522) driven by a hopper lifting roller motor (525).

7. The fully automatic intelligent integrated material handling and packaging equipment according to claim 1, characterized in that: The film coating module (6) includes a film feeding mechanism (64), a film pulling mechanism (62), a film pressing mechanism (63), a cutting mechanism (61), and a pressing table (65); the film feeding mechanism (64) includes a film feeding roller and a tension adjusting roller, the tension adjusting roller being located between the film feeding roller and the guide roller (651) on the pressing table (65); the film pulling mechanism (62) includes a film gripper (622) and a film pulling moving mechanism (621) for driving its movement, the upper clamping plate (6223) and the lower clamping plate (6222) of the film gripper (622) having a serrated anti-slip texture on their respective interlocking surfaces; the pressing roller and the pressing table (65) of the pressing mechanism (63) are both provided with an anti-slip rubber layer; the pressing table (65) has a cutting slit (652) for the blade (612) to pass through and an interlocking notch (653) for the film gripper (622) to extend into.

8. The fully automatic intelligent integrated material feeding and packaging equipment according to claim 1, characterized in that: The control system is a PLC controller, which is connected to the interactive panel (13), each sensor (72), motor and cylinder signal, and is used to preset the material accumulation quantity, regularization stroke and film coating traction length.

9. A control method for the fully automatic intelligent integrated material handling and packaging equipment according to any one of claims 1-8, characterized in that, Includes the following steps: S1: Equipment initialization, empty material box (71) is input through the material box entry mechanism (51) and lifted to the whole material layer (17) through the material box lifting mechanism (52). S2: The feeding module (2) starts, conveys and counts the materials (7) one by one, and pauses after reaching the preset quantity; S3: The material preparation module (3) is started. The quantitative material (7) is pushed into the loading plate (333) and the front end is aligned by the front pushing mechanism (31) and the blocking mechanism (34). This process is repeated until the material (7) in the loading plate (333) reaches the preset batch total amount. Then, the side adjustment mechanism (32) performs side adjustment. S4: The material transfer mechanism (33) transfers the entire batch of materials (7) to the packing station. The suction cup (41) of the packing module (4) descends to grab the materials (7) and puts them into the material box (71). S5: The film coating module (6) starts and sequentially completes film pulling, fixed-length traction, film pressing, cutting and film coating operations; S6: The material box (71) that has been coated is output to the equipment via the material box output mechanism (53).

10. The control method according to claim 9, characterized in that: The preset quantity mentioned in step S2 is 3-10; the preset batch total quantity mentioned in step S3 is 30-50; the control method is executed by the PLC controller to realize fully automated collaborative control.

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