High-precision vertical sorting machine swing arm driving control device

Abstract

This invention provides a high-precision vertical sorting machine swing arm drive control device. The device includes: a rectifier module for connecting to an external power source and providing DC power to the internal circuitry; a control unit connected to the rectifier module; a frequency converter unit connected to both the rectifier module and the control unit, for receiving and executing control signals from the control unit, thereby controlling the swing arm motor to drive the swing arm to run according to a preset motion curve; and a communication module connected to the control unit for data interaction with an external PLC. The control unit is configured to have at least a test mode and an automatic mode. This invention solves the problems in existing technologies caused by centralized PLC control and direct relay drive, such as slow system response, poor control accuracy, large mechanical shock and vibration, and lack of adaptive optimization capabilities.

Description

Technical Field

[0001] This invention relates to the field of electrical and automation control technology, and in particular to a high-precision vertical sorting machine swing arm drive control device. Background Technology

[0002] In modern airport, logistics, and warehousing sorting systems, vertical sorters are key equipment for efficiently utilizing vertical space and achieving rapid sorting of goods. Their performance directly affects the throughput efficiency and reliability of the entire sorting system. Vertical sorters typically integrate multiple execution modules such as conveyors and swing arms. Among these, the precise and rapid drive control of the swing arms is the core technology to ensure accurate execution of sorting actions and avoid damage to goods.

[0003] Traditional vertical sorting machines generally employ a centralized control architecture consisting of a programmable logic controller (PLC) and a control unit (DCU). In this architecture, all logic operations and control instruction generation are centrally processed by the PLC at the higher level; while the lower-level control unit (DCU) primarily contains numerous I / O modules and relays, lacking independent computing capabilities. The PLC acquires field signals through the DCU's I / O modules and then directly drives the swing arm motor to perform simple start-stop actions via the relays within the DCU.

[0004] However, as sorting systems increasingly demand higher efficiency and accuracy, the traditional centralized control schemes have gradually revealed their inherent technical limitations, mainly in the following aspects:

[0005] 1. Because the PLC needs to handle the complex logic tasks of multiple devices in the entire sorting system, its scanning cycle is relatively long. When the PLC controls the swing arm in the form of switch signals through the DCU's IO module, there is a significant delay from detecting the trigger condition to issuing the drive command. This results in a sluggish start and stop response of the swing arm, making it impossible to achieve high-precision point-to-point control. This directly affects the sorting rhythm, and is especially prone to sorting errors in high-speed operation scenarios.

[0006] 2. In relay-contactor drive mode, the swing arm motor is instantaneously subjected to full voltage upon startup and forcibly de-energized for braking upon stopping. This instantaneous start and stop results in sudden braking. The direct consequence is that the swing arm generates strong mechanical vibration and impact noise at the end of its movement. This not only poses a potential risk to the items being sorted (especially vulnerable parts), but also significantly accelerates the fatigue wear of the swing arm mechanism and its connecting components over a long period, significantly shortening the equipment's lifespan and increasing maintenance costs.

[0007] 3. In the traditional centralized control mode, the system relies on long signals issued by the PLC for driving until the signal reaches the target position, at which point the PLC issues a stop command. This architecture, which lacks an independent computing unit, limits the flexible expansion of system functions. The process of fine-tuning and parameter tuning for specific application scenarios is cumbersome, and the system is difficult to achieve flexible adaptation and rapid deployment of control strategies.

[0008] Therefore, there is an urgent need in this field for a new type of swing arm drive control device to solve the problems of slow response, low control accuracy, large mechanical impact and lack of flexible expansion in the existing technology. Summary of the Invention

[0009] To address the shortcomings of existing technologies, this invention provides a high-precision vertical sorting machine swing arm drive control device, which solves the problems of slow system response, poor control accuracy, large mechanical shock and vibration, and lack of adaptive optimization capability caused by PLC centralized control and direct relay drive in existing technologies.

[0010] According to an embodiment of the present invention, a high-precision vertical sorting machine swing arm drive control device includes a swing arm motor, and the device further includes:

[0011] The rectifier module is used to connect to an external power source and provide DC operating power to the internal circuitry of the device.

[0012] The control unit, connected to the rectifier module, is used to monitor the status of each module, process external commands and operating data, and generate corresponding control signals;

[0013] The frequency converter unit is connected to the external power supply, the control unit and the swing arm motor respectively. It is used to convert the external power supply into the frequency converter power required by the swing arm motor and execute the control signal of the control unit so that the swing arm runs according to the preset motion curve.

[0014] The communication module connects to the control unit and is used to establish data communication between the control unit and an external PLC.

[0015] The control unit is configured to have at least a test mode and an automatic mode, and performs the following operations:

[0016] In test mode, the swing arm motor is controlled by the frequency converter to drive the swing arm to perform multiple reciprocating operations. The operation data of the swing arm is measured through the reciprocating operation, and the test operation parameters for controlling the operation of the swing arm are calculated based on the operation data.

[0017] In automatic mode, in response to pulse drive commands received from an external PLC via the communication module and based on the test operation parameters, the swing arm is controlled to automatically complete the full drive stroke from start to stop.

[0018] As a further solution, the device also includes multiple I / O interfaces connected to the control unit; wherein, the first set of I / O interfaces is used to connect the upper position detection switch and the lower position detection switch to receive the upper position signal and the lower position signal of the swing arm, providing the control unit with limit position feedback of the swing arm; the second set of I / O interfaces is used to connect the upper middle layer bag clamping detection photoelectric switch and the lower middle layer bag clamping detection photoelectric switch to receive the upper middle layer bag clamping detection signal and the lower middle layer bag clamping detection signal, providing the control unit with bag clamping detection feedback during the swing arm operation.

[0019] As a further solution, in test mode, the control unit is further configured as follows:

[0020] Execution schedule adjustment:

[0021] The current position of the swing arm is detected; if the upper position signal of the swing arm is detected, the swing arm is controlled to move downward according to the preset motion curve; if the lower position signal of the swing arm is detected, or no position signal is detected, the swing arm is controlled to move upward according to the preset motion curve; after detecting the upper position signal and the lower position signal of the swing arm, the stroke is adjusted.

[0022] Parameter measurement:

[0023] After the stroke is set, the drive arm moves from the current position to the opposite direction to the opposite limit, and then drives it back to the original limit. The single-trip running time or number of pulses of the arm in the upward and downward directions is recorded respectively.

[0024] Execution parameter calculation:

[0025] The drive arm repeatedly performs the parameter measurement operation to reach a preset number of reciprocations, and based on the running time or pulse count measured multiple times, the average running time or average pulse count of the swing arm in the upward and downward directions is calculated respectively to determine the test running parameters.

[0026] As a further solution, the control unit is also configured to include a manual mode, wherein in the manual mode, the control unit is further configured to:

[0027] Responds to manual drive commands for upward or downward movement;

[0028] Based on the type of manual drive command and the current position of the swing arm, control the swing arm to swing in the target direction according to the preset motion curve;

[0029] During the swinging process, if an upper / lower position signal is detected, the swing arm will be stopped; if the running time exceeds the set timeout protection time and no position signal is detected, the swing arm will be stopped and a fault alarm will be triggered.

[0030] As a further solution, in automatic mode, the control unit is further configured to:

[0031] Responds to upward or downward swing pulse drive commands;

[0032] Based on the type of the pulse drive command and the current position of the swing arm, control the swing arm to swing in the target direction according to the preset motion curve;

[0033] During the swinging process, if an upper / lower position signal is detected, the swing arm will be stopped; if the running time exceeds the set timeout protection time and no position signal is detected, the swing arm will be stopped and a fault alarm will be triggered.

[0034] As a further solution, the preset motion curves sequentially include:

[0035] During the slow start-up phase, the operating frequency is increased from the initial frequency to the rated operating frequency according to the frequency increase slope.

[0036] During the travel phase, the operating frequency remains at the rated operating power frequency;

[0037] During the slow-down phase, the operating frequency is reduced from the rated operating frequency to the initial frequency according to the frequency reduction slope.

[0038] As a further solution, during the pausing phase, if the swing arm is not detected to be in position after the operating frequency has dropped to the initial frequency, the swing arm is controlled to continue operating at the initial frequency until the position signal is detected.

[0039] As a further solution, in any of the test mode, manual mode and automatic mode, the control unit monitors the device's emergency stop, fault and power failure status in real time, and immediately interrupts the current operation and triggers a fault alarm when any of the aforementioned statuses are detected.

[0040] Compared with the prior art, the present invention has the following beneficial effects:

[0041] 1. This invention completely decouples the real-time motion control function of the swing arm from the central PLC by using a control unit with autonomous computing capabilities. In automatic mode, the PLC only needs to issue a simple pulse command, while the subsequent complex operation control is completed autonomously by the control unit. This fundamentally avoids the instruction delay caused by the long PLC scan cycle and numerous tasks in the traditional architecture, thus improving the system response speed. At the same time, based on the test operation parameters that are self-tuned in test mode, the swing arm can achieve precise point-to-point control, greatly reducing the sorting error rate.

[0042] 2. This invention uses a preset motion curve to flexibly drive the swing arm motor, replacing the violent "instant start-stop" drive mode of traditional relay control. The swing arm experiences smooth acceleration changes throughout its operation, effectively avoiding the sudden braking effect at the end, thus minimizing mechanical vibration and impact noise. This not only improves the stability and quietness of the equipment during operation but also fundamentally reduces fatigue wear on key mechanical components, providing core technological support for the long-term reliable operation and extended lifespan of the vertical sorting machine.

[0043] 3. This device enables the drive unit to have self-learning capabilities through the parameter self-tuning function in the test mode. It can automatically identify and adapt to different mechanical loads and stroke characteristics, and generate test operation parameters, which fundamentally solves the pain points of traditional system debugging relying on manual experience and parameter fixation making optimization difficult. Attached Figure Description

[0044] Figure 1 This is a structural block diagram of a high-precision vertical sorting machine swing arm drive control device according to an embodiment of this application;

[0045] Figure 2 This is a schematic diagram of the electrical principle of a high-precision vertical sorting machine swing arm drive control device according to an embodiment of this application;

[0046] Figure 3 This is a schematic diagram of the control logic of the vertical sorting machine arm in one embodiment of this application;

[0047] Figure 4 This is a flowchart illustrating the operation control of the swing arm in automatic mode in one embodiment of this application. Detailed Implementation

[0048] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of the present invention, but not all embodiments.

[0049] like Figure 1 As shown in the figure, an embodiment of the present invention proposes a high-precision vertical sorting machine swing arm drive control device, including a swing arm motor, and the device further includes:

[0050] The rectifier module is used to connect to an external power source and provide DC operating power to the internal circuitry of the device.

[0051] The control unit, connected to the rectifier module, is used to monitor the status of each module, process external commands and operating data, and generate corresponding control signals;

[0052] The frequency converter unit is connected to the external power supply, the control unit and the swing arm motor respectively. It is used to convert the external power supply into the frequency converter power required by the swing arm motor and execute the control signal of the control unit so that the swing arm runs according to the preset motion curve.

[0053] The communication module connects to the control unit and is used to establish data communication between the control unit and an external PLC.

[0054] The control unit is configured to have at least a test mode and an automatic mode, and performs the following operations:

[0055] In test mode, the swing arm motor is controlled by the frequency converter to drive the swing arm to perform multiple reciprocating operations. The operation data of the swing arm is measured through the reciprocating operation, and the test operation parameters for controlling the operation of the swing arm are calculated based on the operation data.

[0056] In automatic mode, in response to pulse drive commands received from an external PLC via the communication module and based on the test operation parameters, the swing arm is controlled to automatically complete the full drive stroke from start to stop.

[0057] See Figure 2 The electrical schematic diagram of this embodiment mainly integrates a rectifier module, a frequency converter, a communication module, and a control unit with autonomous computing and management capabilities. This decouples the swing arm drive control from the traditional PLC, achieving higher precision and lower impact intelligent control. The device specifically includes the following core components:

[0058] The rectifier module is used to connect to the external power supply line and convert AC power into stable DC power, providing 24V DC power to external detection sensors and communication modules, and providing stable 5V DC power to internal control units, frequency converters and other circuits.

[0059] The control unit, as the control core of the device, is preferably an embedded microprocessor such as an STM32 microcontroller, DSP, or ARM. It is responsible for performing control logic operations based on IO data, PLC instructions, and test parameters, and for real-time control of the swing arm motor according to the operation results.

[0060] The frequency converter unit has its input end connected to an external power source to obtain DC power, its control end connected to a control unit to receive control signals such as PWM, and its output end connected to the swing arm motor to provide frequency converter power to the vertical swing arm motor and smoothly adjust the speed of the motor according to the load and control requirements.

[0061] The communication module connects to the control unit and is used for high-speed data interaction with an external PLC, receiving remote control commands from the PLC, and providing feedback on the device's real-time status, fault information, and other operating results.

[0062] The control unit is configured to have at least a test mode and an automatic mode.

[0063] When in test mode, the control unit controls the frequency converter to drive the swing arm motor, causing the swing arm to reciprocate multiple times. Through this reciprocating motion, the control unit measures the swing arm's operating data and calculates the test operating parameters used to control the swing arm's operation based on this data. This process enables the device to learn and optimize its own characteristics and load parameters.

[0064] When in automatic mode, the control unit receives pulse drive commands from an external PLC through the communication module and responds accordingly. Based on the test operation parameters calculated in test mode, the control unit controls the swing arm to automatically complete the full drive stroke from start to stop without PLC intervention in the specific acceleration, constant speed and deceleration processes.

[0065] It should be noted that, to enhance the stability and maintainability of the device, an isolating switch is installed between the power input line and the frequency converter and / or rectifier module. This switch is used to quickly disconnect the power supply circuit in case of overcurrent or short circuit, providing reliable protection for the device and external lines and improving system safety. Furthermore, the control unit integrates isolating switch status monitoring, real-time input voltage monitoring, and power loss detection functions on top of its original features. The self-diagnostic and protection module inside the control unit can collect real-time data on power quality, switch status, and load power changes. Once an anomaly is detected, it can proactively implement corresponding control strategies or report fault information.

[0066] Through the above method, this device successfully decouples the real-time drive and motion control functions of the swing arm from the traditional central PLC. The PLC is simplified to issuing simple start / stop pulse commands, while all complex, real-time control calculations are autonomously completed by the internal control unit of this device. This fundamentally solves the problems of instruction delay and slow system response caused by the long scan cycle and numerous tasks of the PLC, and achieves high-precision positioning control through self-tuning parameters. In test mode, it can automatically tune parameters, learn the actual operating characteristics of the swing arm, and generate optimal test operating parameters. In automatic operation, based on these parameters, it autonomously completes a complete and smooth drive stroke including acceleration, constant speed, and deceleration, replacing the traditional instantaneous start / stop violent drive method, fundamentally eliminating the sudden braking phenomenon of the swing arm, significantly reducing mechanical vibration and impact noise, and effectively extending the service life of the mechanical structure.

[0067] As an independent intelligent drive unit, this device possesses the capabilities of self-learning, self-optimization, and self-execution. This eliminates the reliance on fixed programs in the PLC for swing arm control, greatly enhancing the system's flexibility. For different installation scenarios and mechanical loads, the device can automatically adapt to optimal parameters, simplifying the debugging process and improving the system's portability and overall performance.

[0068] As a further solution, the device also includes multiple I / O interfaces connected to the control unit; these are used to expand the device's field signal acquisition capabilities, thereby enabling comprehensive monitoring of the swing arm's operating status and the surrounding environment. The first set of I / O interfaces is used to connect physical limit switches, specifically including:

[0069] One interface connects to an upper limit detection switch, including a mechanical limit switch or proximity switch, installed at the extreme position of the swing arm's upward swing. When the swing arm reaches this position, the switch actuates, inputting a high-level or low-level upper limit signal to the control unit. Another interface connects to a lower limit detection switch, installed at the extreme position of the swing arm's downward swing, to provide a lower limit signal. This set of interfaces provides feedback on the swing arm's extreme positions to the control unit.

[0070] The second set of I / O interfaces is used to connect photoelectric sensing devices, specifically including:

[0071] One interface connects to the upper-middle layer baggage detection photoelectric switch, whose light curtain spans the baggage passage path on the upper layer of the swing arm. The other interface connects to the lower-middle layer baggage detection photoelectric switch, whose light curtain corresponds to the baggage passage path on the lower layer of the swing arm. When baggage is accidentally caught or protrudes during swing arm operation (i.e., "baggage clamping") and obstructs the light curtain, the corresponding photoelectric switch is triggered, sending either an upper-middle layer baggage detection signal or a lower-middle layer baggage detection signal to the control unit. This provides real-time baggage clamping detection feedback to the control unit. Upon receiving such a signal, the control unit can immediately implement safety strategies such as emergency shutdown, effectively preventing equipment damage and baggage damage.

[0072] Referring to Table 1, in this embodiment, four IO points need to be connected before measuring parameters in test mode. By default, all of them are input signals, namely "swing arm motor upper position detection", "swing arm motor lower position detection", "upper middle layer bag clamping detection photoelectric", and "middle and lower layer bag clamping detection photoelectric". Each IO signal has a built-in default filtering time. IO1 and IO2 are used to monitor whether the swing arm is in position, and IO3 and IO4 are bag clamping signals. When this signal is set to "0", the controller stops the swing arm and reports an error.

[0073] Table 1. I / O Point Definitions and Functions

[0074]

[0075] like Figure 3 As a further solution, in test mode, the control unit is further configured to execute a complete parameter self-tuning process. The purpose is to allow the device to autonomously learn the motion characteristics of the currently connected mechanical structure, thereby laying the foundation for high-precision automatic control. This process includes the following three stages:

[0076] 1. Itinerary planning stage:

[0077] The control unit first checks the status of the I / O interface to detect the current position of the swing arm. If a valid upper position signal is detected, the swing arm is determined to be in the upper position, and the variable frequency unit is then controlled to drive the swing arm motor, causing the swing arm to slowly move downwards according to a preset motion curve. If a valid lower position signal is detected, or no position signal is detected (e.g., in an unknown intermediate position), the control unit controls the swing arm to slowly move upwards according to the preset motion curve. The purpose of this process is to traverse the entire physical stroke of the swing arm. The control unit continuously monitors the process until it successfully acquires a valid upper position signal and a valid lower position signal. At this point, the device completes the spatial mapping of the swing arm's motion range, and the stroke tuning phase ends.

[0078] 2. Parameter Measurement Stage:

[0079] After defining the stroke range, the device begins measuring the test operating parameters used to control the swing arm's movement. The control unit drives the swing arm to complete one full reciprocating cycle. For example, if the swing arm stops at the upper position after the stroke is set, it is controlled to move downwards to the lower position, and the downward movement time or pulse count is recorded. Subsequently, the swing arm is immediately controlled to return from the lower position to the upper position, and the upward movement time or pulse count is recorded. This reciprocating process records the swing arm's operating data under a complete drive stroke.

[0080] 3. Parameter calculation stage:

[0081] To obtain more accurate and reliable test parameters, the control unit drives the swing arm to repeatedly perform the above parameter measurement operation. After completing a preset 2m reciprocating cycle, the system statistically processes the multiple operational data collected during this period (including directly measured running time, pulse count, and equivalent time obtained based on pulse equivalent conversion). The average single-trip running time or average single-trip pulse count of the swing arm in the upward and downward directions is calculated using the following formulas:

[0082] Tp = (Tp1 + Tp2 + Tp3, ... + Tpm) / m, where Tp represents the average uplink time or number of pulses, Tp1, Tp2, Tp3, ..., Tpm represent the single uplink time or number of pulses, and m represents the total number of measurements;

[0083] Tb = (Tb1 + Tb2 + Tb3, ... + Tbn) / m, where Tb represents the average downlink time or number of pulses, Tb1, Tb2, Tb3, ..., Tbm represent the downlink time or number of pulses per cycle, and m represents the total number of measurements.

[0084] Finally, the calculated average running time or average number of pulses per trip is determined as the test running parameter of the swing arm under this specific working condition and stored in non-volatile memory.

[0085] Through the automated tuning process in test mode, the drive control device provided by this invention has a strong adaptive capability, which can automatically adapt to different mechanical installation and load conditions, providing core parameter guarantees for achieving high-precision and high-consistency control performance.

[0086] As a further solution, the control unit is also configured to include a manual mode. In the manual mode, the control unit is further configured to: respond to a user-triggered up or down manual drive command, and determine the permissible target direction of operation based on the real-time current position of the swing arm; control the swing arm to swing towards the target position according to the determined target direction, and monitor the positioning signal in real time during the entire swing of the swing arm; once the swing arm reaches the upper or lower position signal in the target direction is detected, immediately control the swing arm to stop smoothly; if the continuous running time exceeds the set timeout protection time from the start of the swing and the corresponding positioning signal is still not detected, immediately control the swing arm to stop, and generate and report fault alarm information to indicate possible mechanical jamming or sensor failure.

[0087] As a further solution, in automatic mode, the control unit is further configured to: respond to an up or down swing pulse drive command; control the swing arm to swing in the target direction according to a preset motion curve based on the type of the pulse drive command and the current position of the swing arm; during the swing, if an up / down position signal of the swing arm is detected, control it to stop; if the running time exceeds the set timeout protection time and no position signal is detected, control it to stop and trigger a fault alarm.

[0088] In response to the rising edge pulse of the pulse drive command, and based on the test operation parameters, the swing arm is controlled to run the full drive stroke according to the preset motion curve, and automatically stops when the swing arm is detected to be in position during the deceleration phase.

[0089] like Figure 4As shown, in a preferred embodiment of the present invention, in automatic mode, the control unit is further configured to execute a complete, safe, and intelligent single-instruction triggering process. This process is an improvement on the traditional "PLC long signal drive, PLC sends stop command after reaching the target position" control method. Its core lies in the control unit driving the swing arm to complete the entire drive stroke (from start, acceleration, constant speed, deceleration to stop), while the upper-level PLC only needs to issue a simple pulse command as a start trigger. Its specific working process is as follows:

[0090] The control unit continuously monitors control commands from an external PLC via a communication module. Upon receiving an upward or downward swing pulse drive command (typically a high-level pulse or a specific command bit in a communication message), the control unit immediately responds to the command upon recognizing its rising edge. The control unit parses the command type (upward or downward) and simultaneously queries the current position of the swing arm obtained through the I / O interface (e.g., whether it is currently in the upper or lower position). Based on the parsed command type and the current position of the swing arm, the control unit determines the rationality of the action (e.g., if an upward swing command is received and the swing arm is already in the upper position, the command can be ignored or an error can be reported). Subsequently, it calls the pre-stored test running parameters and preset motion curves, sends a control signal to the frequency converter unit, drives the swing arm motor, and causes the swing arm to accelerate and slowly start in the target direction (upward or downward). Once the operating frequency accelerates to the rated operating frequency, it enters a constant speed phase, maintaining a constant speed at this frequency. When the control unit determines that the swing arm has entered the preset deceleration zone based on the running time or pulse count, it initiates the slow-stop phase. The operating frequency begins to decrease according to the preset frequency reduction slope. This deceleration process also follows the parameters (test time) set in test mode. During deceleration, the control unit continuously monitors the upper / lower position detection switch signal of the IO interface. Once a valid upper / lower position signal of the swing arm is detected, it immediately controls the swing arm motor to stop, completing the entire swing stroke.

[0091] The preset motion curve ensures that the swing arm experiences smooth acceleration, stable constant speed operation, and smooth deceleration before stopping, thus effectively avoiding mechanical shock during the start-stop phase.

[0092] Throughout the entire swing of the swing arm, the control unit performs two parallel stop decisions, forming a double safety mechanism:

[0093] Normal Stop: After the swing arm enters the deceleration phase, the control unit begins to monitor the corresponding I / O interface in real time. Once a valid swing arm upper position signal (for the upward swing command) or swing arm lower position signal (for the downward swing command) is detected, a stop command is immediately issued to bring the swing arm motor to a precise stop.

[0094] Fault Stop: Simultaneously, the control unit starts timing from the start time. If the swing arm's running time exceeds the pre-set timeout protection time based on the test running parameters, and the target positioning signal is still not detected, an abnormality is determined (such as a positioning sensor malfunction or mechanical jamming). At this time, the control unit will immediately force a stop operation and trigger a fault alarm signal to the external PLC via the communication module, thereby effectively preventing equipment damage.

[0095] It should be noted that the timeout protection time described in this embodiment is derived from parameters obtained through self-tuning in test mode. Specifically, this time is the average total running time or average total number of pulses for the swing arm to perform one complete reciprocating cycle (i.e., the sum of the upward and downward strokes), and its calculation formula is defined as: To = Tp + Tb, where,

[0096] To represents the average total running time or total number of pulses for a complete reciprocating cycle, i.e., the set timeout protection time;

[0097] Tp represents the average running time or average number of pulses for a single uplink trip;

[0098] Tb represents the average running time or average number of pulses for a single downlink trip.

[0099] Through the above process, this invention completely avoids the adverse effects of signal transmission delay and PLC execution cycle caused by the traditional control method of "the PLC issuing a stop command after detecting the upper position". It simplifies a complex control process that originally required real-time PLC intervention into one initiated by the PLC, with all complex real-time control, status judgment and safety protection logic completed autonomously by this device, thereby greatly improving the system's response speed, control accuracy and operational reliability.

[0100] As a further solution, the preset motion curves sequentially include:

[0101] During the slow start-up phase, the operating frequency is increased from the initial frequency to the rated operating frequency according to the frequency increase slope.

[0102] During the travel phase, the operating frequency remains at the rated operating power frequency;

[0103] During the slow-down phase, the operating frequency is reduced from the rated operating frequency to the initial frequency according to the frequency reduction slope.

[0104] In this embodiment, the initial frequency can be either the default value Fd or the set value Fs by the controller. Taking the above operation with the default value Fd as the initial frequency as an example, the specific frequency control strategy is shown in Table 2:

[0105] Table 2: Frequency Control of Swing Arm Oscillation Process

[0106]

[0107] Slow Start Phase: During the start-up period Tacc, the control arm starts from the initial frequency (in this embodiment, the default value Fd or the set value Fs) and gradually increases to the rated operating frequency of 50Hz according to the frequency ramp (50 / Tacc). The time required for this phase is: (50-Fd)*Tacc / 50.

[0108] Traveling phase: The control arm maintains a constant speed at the rated operating frequency of 50Hz. The duration of this phase is: Tp-(50-Fd)*Tacc / 50-(50-Fd)*Tdec / 50;

[0109] Stopping phase: During the deceleration period Tdec, the control arm gradually decreases from the rated operating frequency of 50Hz to the initial frequency at a frequency reduction slope of (50 / Tdec). The time taken for this phase is: (50-Fd)*Tdec / 50.

[0110] In this embodiment, during the pausing phase, if the swing arm is not detected to be in position after the operating frequency has dropped to the initial frequency, the swing arm is controlled to continue running at the initial frequency Fd (or Fs) until the position signal is detected.

[0111] As a further solution, in any of the test mode, manual mode and automatic mode, the control unit monitors the device's emergency stop, fault and power failure status in real time, and immediately interrupts the current operation and triggers a fault alarm when any of the aforementioned statuses are detected.

[0112] This embodiment proposes a safety monitoring and fault handling mechanism. This mechanism operates independently of the device's current operating mode (test, manual, or automatic), continuously running as a fundamental service to ensure system safety. It ensures that the device can respond quickly to sudden internal and external hazards regardless of the operating mode. This upgrade from "passive protection" to "active protection" significantly improves the safety and reliability of the entire vertical sorting machine system, effectively preventing equipment damage and safety accidents that may occur due to control logic delays in abnormal conditions.

[0113] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A high-precision vertical sorting machine swing arm drive control device, comprising a swing arm motor, characterized in that, The device further includes: The rectifier module is used to connect to an external power source and provide DC operating power to the internal circuitry of the device. The control unit, connected to the rectifier module, is used to monitor the status of each module, process external commands and operating data, and generate corresponding control signals; The frequency converter unit is connected to the external power supply, the control unit and the swing arm motor respectively. It is used to convert the external power supply into the frequency converter power required by the swing arm motor and execute the control signal of the control unit so that the swing arm runs according to the preset motion curve. The communication module connects to the control unit and is used to establish data communication between the control unit and an external PLC. The control unit is configured to have at least a test mode and an automatic mode, and performs the following operations: In test mode, the swing arm motor is controlled by the frequency converter to drive the swing arm to perform multiple reciprocating operations. The operation data of the swing arm is measured through the reciprocating operation, and the test operation parameters for controlling the operation of the swing arm are calculated based on the operation data. In automatic mode, in response to the pulse drive command received from the external PLC through the communication module, and based on the test operation parameters, the swing arm is controlled to automatically complete the full drive stroke from start to stop. The device also includes multiple I / O interfaces connected to the control unit; wherein, the first set of I / O interfaces is used to connect the upper position detection switch and the lower position detection switch to receive the upper position signal and the lower position signal of the swing arm, providing the control unit with limit position feedback of the swing arm; the second set of I / O interfaces is used to connect the upper middle layer bag clamping detection photoelectric switch and the lower middle layer bag clamping detection photoelectric switch to receive the upper middle layer bag clamping detection signal and the lower middle layer bag clamping detection signal, providing the control unit with bag clamping detection feedback during the swing arm operation. In test mode, the control unit is further configured as follows: Execution schedule adjustment: The current position of the swing arm is detected; if the upper position signal of the swing arm is detected, the swing arm is controlled to move downward according to the preset motion curve; if the lower position signal of the swing arm is detected, or no position signal is detected, the swing arm is controlled to move upward according to the preset motion curve; after detecting the upper position signal and the lower position signal of the swing arm, the stroke is adjusted. Parameter measurement: After the stroke is set, the drive arm moves from the current position to the opposite direction to the opposite limit, and then drives it back to the original limit. The single-trip running time or number of pulses of the arm in the upward and downward directions is recorded respectively. Execution parameter calculation: The drive arm repeatedly performs the parameter measurement operation to reach a preset number of reciprocations, and based on the running time or pulse count measured multiple times, the average running time or average pulse count of the swing arm in the upward and downward directions is calculated respectively to determine the test running parameters.

2. The high-precision vertical sorting machine swing arm drive control device as described in claim 1, characterized in that, The control unit is also configured to include a manual mode, wherein in the manual mode, the control unit is further configured to: Responds to manual drive commands for upward or downward movement; Based on the type of manual drive command and the current position of the swing arm, control the swing arm to swing in the target direction according to the preset motion curve; If a signal indicating that the swing arm has reached its upper / lower position is detected during the swing process, the swing arm will be stopped. If the running time exceeds the set timeout protection time and no arrival signal is detected, the system will be stopped and a fault alarm will be triggered.

3. The high-precision vertical sorting machine swing arm drive control device as described in claim 1, characterized in that, In automatic mode, the control unit is further configured to: Responds to upward or downward swing pulse drive commands; Based on the type of the pulse drive command and the current position of the swing arm, control the swing arm to swing in the target direction according to the preset motion curve; If a signal indicating that the swing arm has reached its upper / lower position is detected during the swing process, the swing arm will be stopped. If the running time exceeds the set timeout protection time and no arrival signal is detected, the system will be stopped and a fault alarm will be triggered.

4. A high-precision vertical sorting machine swing arm drive control device as described in any one of claims 1 to 3, characterized in that, The preset motion curves sequentially include: During the slow start-up phase, the operating frequency is increased from the initial frequency to the rated operating frequency according to the frequency increase slope. During the travel phase, the operating frequency remains at the rated operating power frequency; During the slow-down phase, the operating frequency is reduced from the rated operating frequency to the initial frequency according to the frequency reduction slope.

5. The high-precision vertical sorting machine swing arm drive control device as described in claim 4, characterized in that, During the pausing phase, if the swing arm is not detected to be in position after the operating frequency has dropped to the initial frequency, the swing arm is controlled to continue operating at the initial frequency until the position signal is detected.

6. The high-precision vertical sorting machine swing arm drive control device as described in claim 4, characterized in that, In any of the test mode, manual mode, and automatic mode, the control unit monitors the device's emergency stop, fault, and power failure status in real time, and immediately interrupts the current operation and triggers a fault alarm when any of the aforementioned statuses are detected.

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