Automatic intelligent grading equipment and method for carya illinoensis

Abstract

The invention relates to the technical field of agricultural product processing, in particular to carya illinoensis automatic intelligent grading equipment and method.The grading equipment comprises a transmission mechanism, and the transmission mechanism comprises a conveying roller used for bearing walnuts and a first driving assembly used for driving a driver to move; the visual detection mechanism comprises at least one visual camera which is arranged on one side of the transmission mechanism and is used for collecting appearance images of the carya illinoensis so as to identify whether the carya illinoensis is damaged or not; and the sorting execution mechanism comprises a plurality of movably arranged sorting rollers and a second driving assembly for driving a driver to move. By constructing a full-automatic closed-loop system of conveying, detecting, decision making and executing, the consistency leap of sorting efficiency and quality is achieved, the working mechanism that sorting roller rotation cooperates with a visual camera is adopted, walnuts naturally roll in the conveying process, 360-degree dead-corner-free image collection is achieved, and the quality of the walnuts is improved. The problems of missing detection and misjudgment caused by visual fatigue and detection blind areas in traditional manual sorting are fundamentally solved.

Description

Technical Field

[0001] This invention relates to the field of agricultural product processing technology, specifically to an automated intelligent grading device and method for thin-shelled pecans. Background Technology

[0002] As a high-value nut variety, the market value of thin-shelled pecans is closely related to their appearance and quality. The presence of defects such as cracks and mold on the surface is a key factor determining their grade and price. With rising consumer demand and increasingly stringent market requirements for agricultural product quality, traditional grading methods are no longer sufficient to meet the needs of industrialization and standardization.

[0003] Currently, the sorting of thin-shelled pecans mainly relies on the following methods: 1. Manual sorting is still the main choice for most small and medium-sized enterprises. This method relies on manual judgment and sorting by eye and experience. In actual operation, sorting workers need to quickly identify a large number of walnuts with similar appearance and color under high intensity lighting, which can easily lead to visual fatigue and affect the sorting accuracy. 2. Mechanical screening has achieved automation to a certain extent, but its functions are relatively simple. These types of equipment mostly use physical size or weight sorting principles for sorting. Sorting by size and weight cannot identify surface features such as color, texture, and cracks, which affects the quality of the sorted products. 3. While basic image recognition sorting represents the future direction of technology, numerous technical challenges remain in its implementation. Firstly, the problem of blind spots in detection is prominent. During conventional conveyor belt transport, only a portion of the walnut's surface is typically exposed to the camera's field of view, making it impossible to detect defects on the bottom and sides, resulting in a high false positive rate. Summary of the Invention

[0004] To address the problems in the existing technology, the present invention provides an automated intelligent grading device for thin-shelled pecans.

[0005] The technical solution adopted by the present invention to solve its technical problem is: an automated intelligent grading device for thin-shelled pecans, including a transmission mechanism, which includes a conveyor roller for carrying pecans and a first drive component for the movement of the driver. A visual inspection mechanism includes at least one visual camera disposed on one side of the transmission mechanism for acquiring images of the appearance of thin-shelled pecans to identify whether they are damaged. The sorting actuator includes multiple movably arranged sorting rollers and a second drive assembly for moving the drive; the sorting rollers have cavities inside, and a high-pressure air pump is connected to one side of the cavity; The control mechanism is electrically connected to the vision camera and the high-pressure air pump. The control mechanism is used to start the high-pressure air pump based on the vision analysis structure to blow the walnuts into the corresponding sorting box.

[0006] This invention also provides a method for grading thin-shelled pecans, using an automated intelligent grading device for thin-shelled pecans. The method includes the following steps: S1. Connect the control terminal to the control mechanism in the grading equipment. The control terminal is used to receive detection data, set grading parameters and monitor the equipment operation status. The walnuts are transported to the sorting execution mechanism through the conveying mechanism. S2. During the transportation process, images of the walnuts are collected by a visual inspection mechanism; S3. The control mechanism analyzes the acquired images, identifies surface defects of the walnuts, and determines the grade of the walnuts. S4. When Hetai moves to the sorting station corresponding to the target sorting box, the control mechanism controls the high-pressure air pump in the corresponding sorting roller to start, blowing the walnuts into the target sorting box for grading.

[0007] The beneficial effects of this invention are:

[0008] I. This invention achieves a significant leap in both sorting efficiency and quality by constructing a fully automated closed-loop system encompassing conveying, detection, decision-making, and execution. The equipment employs a collaborative working mechanism of rotating sorting rollers and a vision camera, allowing the walnuts to tumble naturally during transport. This enables 360° image acquisition without blind spots, fundamentally solving the problems of missed detections and misjudgments caused by visual fatigue and blind spots in traditional manual sorting. Combined with intelligent image recognition algorithms, it can accurately identify surface defects such as cracks and mold, and precisely classify them according to their severity, significantly improving sorting accuracy.

[0009] II. This invention, through the ingenious design of the friction plate and rotating wheel, transforms the horizontal movement of the sorting roller into rotation, greatly simplifying the mechanical structure and reducing manufacturing costs and failure rates. The counterweight within the sorting roller effectively improves operational stability and suppresses vibration during high-speed start-up and shutdown. Simultaneously, the trigger-type pneumatic sorting scheme based on physical contact conduction provides rapid response and precise control, enabling on-demand energy supply and avoiding the high energy consumption problem of continuous air blowing. The equipment has a robust structure, is easy to maintain, and effectively reduces long-term operation and maintenance and energy costs, providing reliable support for large-scale, intensive production. Attached Figure Description

[0010] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0011] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 For the present invention Figure 1 Axis view; Figure 3 This is a schematic diagram of the three-dimensional structure of the sorting roller of the present invention; Figure 4 For the present invention Figure 3 Axis view; Figure 5 This is a cross-sectional view of the sorting roller of the present invention; Figure 6 This is an enlarged schematic diagram of point A in part 5 of the present invention; Figure 7 This is a schematic diagram of the three-dimensional structure of the counterweight block of the present invention; Figure 8 This is the overall flowchart of the present invention.

[0012] In the diagram: 100-Conveyor roller; 110-First drive gear; 120-Motor; 130-Chain; 140-Second drive gear; 200-Sorting support frame; 210-Working box; 220-Vision camera; 230-Integrated conductive cover; 231-Circuit board; 232-Electrical contact; 240-Sorting box; 250-Transmission belt; 260-Sorting roller; 261-Inclined through hole; 262-Hollow shaft; 263-Conductive contact; 264-Counterweight; 2641-Air guide groove; 2642-Arc-shaped plate; 265-Cavity; 266-High-pressure air pump; 267-Universal connector; 270-Friction plate; 280-Rotating wheel; 281-Spring. Detailed Implementation

[0013] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0014] like Figures 1-8 As shown, an automated intelligent grading device for thin-shelled pecans according to the present invention includes a transmission mechanism, which includes a conveyor roller 100 for carrying pecans and a first drive component for driving the motion of the driver. A visual inspection mechanism includes at least one visual camera 220 disposed on one side of the transmission mechanism for acquiring images of the appearance of thin-shelled pecans to identify whether they are damaged. The sorting actuator includes a plurality of movably arranged sorting rollers 260 and a second drive assembly for moving the driver; the sorting rollers 260 have cavities 265 inside, and a high-pressure air pump 266 is connected to one side of the cavity 265. The control mechanism is electrically connected to the vision camera 220 and the high-pressure air pump 266, and is used to start the high-pressure air pump 266 based on the vision analysis structure to blow the walnuts into the corresponding sorting box 240.

[0015] The conveying mechanism is responsible for the continuous feeding of walnuts. The first drive component includes a motor 120 for power output. The output head of the motor 120 provides power for the rotation of the conveying roller 100. The conveying roller 100 enables the walnuts to be conveyed parallel to the axis of the conveying roller 100. The conveying roller 100 conveys the walnuts between two sorting rollers 260. The sorting roller 260 is designed with a concave center and a convex edge. Thin-shelled walnuts are mainly long elliptical. The outer wall of the sorting roller 260 is rough, which can drive the walnuts to rotate at the same time during the rotation of the sorting roller 260. The working box 210 can cover the sorting roller 260 inside to prevent the walnuts from flying out.

[0016] The output end of the motor 120 also drives the first drive gear 110 to rotate. The first drive gear 110 drives the second drive gear 140 to rotate through the chain 130. The second drive gear 140 transmits power to the transmission belt 250 through the shaft. In this embodiment, the visual inspection mechanism can acquire images of the walnut's appearance. The visual camera 220 is a 20-megapixel industrial camera, which can clearly capture the outer wall of the walnut. During the transportation of the walnut, the rotation of the sorting roller 260 drives the walnut to rotate, so that the walnut rotates together. In cooperation with the visual camera 220, the walnut can be monitored 360° without blind spots. The visual camera 220 transmits the acquired images to the control mechanism. The control mechanism identifies the images, performs grade analysis, and makes decisions. When the walnut moves to the sorting station, the high-pressure air pump 266 in the target sorting roller 260 is started, and the airflow blows the walnut into the matching sorting box 240.

[0017] The fully automated process from conveying to sorting replaces manual grading, increasing efficiency by 5-8 times; the linkage between visual inspection and sorting start ensures minimal grading consistency error; the gas pressure of the gas injection at the preset position is within the preset range, and if a large fruit is incorrectly identified and passes through the small sorting point, the low power of the high-pressure air pump 266 may not be able to directly blow out the corresponding walnut.

[0018] Walnuts are conveyed at a speed of 0.5 m / s and quickly identified by a vision camera 220. The high-pressure air pump 266 is a miniature air pump with an air pressure that can be adjusted from 0.1 MPa to 0.3 MPa according to actual needs. When opened, it generates a short and strong airflow that can quickly blow the corresponding walnuts out of the sorting roller 260 and into the sorting box 240.

[0019] As a preferred technical solution, the visual inspection mechanism is installed above one end of the sorting support frame 200 near the transmission mechanism. The second drive assembly includes a transmission belt 250 located in the middle of the sorting support frame 200, and the sorting rollers 260 are disposed on both sides of the transmission belt 250 and move with the follower.

[0020] Specifically, the sorting rollers 260 are arranged in pairs on both sides of the transmission belt 250. When the transmission belt 250 moves, the walnuts placed on the two sorting rollers 260 can drive the sorting rollers 260 to move. The sorting support frame 200 is used to support the transmission belt 250 and other components, forming a continuous inspection and sorting production line, ensuring efficiency. Inspection is performed before sorting, resulting in high space utilization. The symmetrical arrangement of the sorting rollers 260 ensures the smooth and stable transport of the walnuts during the conveying process.

[0021] As a preferred technical solution, a friction plate 270 for rotating the sorting roller 260 is fixedly installed in the middle of the sorting support frame 200. The rotating wheel 280 is connected to the transmission belt 250. The rotating wheels 280 drive the sorting roller 260 to rotate on both sides of the transmission belt 250. When the transmission belt 250 moves, the rotating wheel 280 and the friction plate 270 are released from friction and generate rotation, which drives the sorting roller 260 to rotate.

[0022] In this embodiment, the horizontal movement of the sorting roller 260 is converted into rotation around its own axis by the friction between a fixed friction plate 270 and the rotating wheel 280 that moves with the transmission belt 250. During the rotation, the sorting roller 260 can drive the long elliptical thin-shelled pecans to rotate synchronously. This process is beneficial for the vision camera 220 to capture information from all directions, and can sort the thin-shelled pecans more accurately and quickly. A wear-resistant rubber friction plate 270 is fixedly installed on the sorting support frame 200. When the sorting roller 260 rotates to the preset position, the rotating wheels 280 at both ends of the sorting roller 260 will contact the friction plate 270. Under the action of friction, the rotating wheels 280 float, thereby driving the sorting roller 260 to rotate continuously during the movement.

[0023] As a preferred technical solution, the end of the rotating wheel 280 is connected to a universal connector 267. A transverse groove is opened inside the rotating wheel 280. The top of one end of the universal connector 267 inside the rotating wheel 280 is connected to the inner wall of the transverse groove through a spring 281. The outer diameter of the spring 281 is smaller than the inner diameter of the transverse groove.

[0024] Specifically, the universal connector 267 allows relative rotation with the rotating wheel 280, with a certain angular tolerance. The internal spring 281 provides a buffer and adapts to tension, acting as a buffer when the pecans fall between the two sorting rollers 260. When a pecan falls between the two sorting rollers 260, both rollers will tilt slightly. Through the cooperation of the universal connector 267 and the rotating wheel 280, the sorting rollers 260 can still rotate stably during the slight tilt. The tilt of the sorting rollers 260 facilitates the high-pressure air pump 266 to blow the pecans out with air. The vision camera 220 can also upload the tilt angle of the sorting rollers 260. By combining the intuitive image and the tilt angle of the sorting rollers 260, the pecans can be evaluated, which helps to separate empty, substandard pecans from solid, whole pecans, ensuring the quality of the fruit.

[0025] As a preferred technical solution, the universal connector 267 is fixedly connected to a hollow shaft 262 at one end outside the rotating wheel 280. The hollow shaft 262 is connected to the sorting roller 260, and the high-pressure air pump 266 is placed inside the hollow shaft 262.

[0026] The hollow shaft 262 serves as a connector and also houses the high-pressure air pump 266 inside the hollow shaft 262, achieving a compact structure. The easily damaged high-pressure air pump 266 is concentrated in the relatively fixed transmission component hollow shaft 262, which is beneficial for the protection of the high-pressure air pump 266.

[0027] As a preferred technical solution, a counterweight 264 is rotatably arranged inside the sorting roller 260. An arc-shaped piece 2642 on one side of the counterweight 264 extends into the hollow shaft 262. A gas guide groove 2641 for gas guidance is provided in the middle of the counterweight 264. The sorting roller 260 is arranged in a shape that is concave in the middle and convex on both sides. The cavity 265 inside the sorting roller 260 is located near the high-pressure air pump 266. Multiple sets of inclined through holes 261 are opened on the side wall of the sorting roller 260 and communicate with the internal cavity 265.

[0028] During the rotation of the sorting roller 260, the counterweight 264 has one side of its arc-shaped plate 2642 hanging down naturally, so that no matter how the sorting roller 260 rotates, the counterweight 264 can play a role in stabilizing the center of gravity. During the movement of the equipment, even if the transmission belt 250 starts or stops rapidly, the sorting roller 260 will not swing violently due to the stabilizing effect of the counterweight 264.

[0029] The air guide groove 2641 can concentrate the airflow generated by the high-pressure air pump 266, ensuring that the airflow energy is concentrated and ejected from the inclined through hole 261. The counterweight 264 can block the inclined through hole 261 located in the lower half of the sorting roller 260 at all times, reducing the waste of high-pressure gas. The sorting roller 260 is concave in the middle and protruding on both sides, which makes it easy to store and stabilize the walnuts. The walnuts will not slip out when the sorting roller 260 is tilted.

[0030] As a preferred technical solution, the control mechanism includes a conductive integrated cover 230, and a circuit board 231 is disposed inside the conductive integrated cover 230; Electrical contact 232 is provided on conductive integrated cover 230. Conductive contact 263 is provided on the outside of hollow shaft 262. When sorting roller 260 moves to sorting station, electrical contact 232 and conductive contact 263 make contact and conduct electricity to power high pressure air pump 266.

[0031] The high-pressure air pump 266 is supplied with instantaneous power by using physical contact 232 to connect with conductive contact 263. The contacts only make contact when the sorting roller 260 moves to the preset sorting position, and the high-pressure air pump 266 will work. It has a fast response and high reliability.

[0032] This invention also provides a method for grading thin-shelled pecans, comprising the following steps: The method includes a management computer, which is communicatively connected to the control mechanism in the grading equipment, for receiving detection data, setting grading parameters, and monitoring the equipment's operating status, and for conveying walnuts to the sorting execution mechanism via a conveying mechanism. S1. During the transportation process, images of the walnuts are collected by a visual inspection mechanism; S2. The control mechanism analyzes the acquired images, identifies surface defects of the walnuts, and determines the grade of the walnuts. S3. When the walnuts move to the sorting station corresponding to the target sorting box 240, the control mechanism controls the high-pressure air pump 266 in the corresponding sorting roller 260 to start, blowing the walnuts into the target sorting box 240 for grading.

[0033] The management computer communicates with the control mechanism, receives visual inspection data and grading parameters, and analyzes the quality of the walnut by combining the appearance of the walnut and the tilt angle of the sorting roller 260 during multiple visual capture processes. The grading process is digitally managed, supports dynamic parameter adjustment, and can monitor the equipment's movement status in real time, thus improving operation and maintenance efficiency.

[0034] S4. The entire process from the transfer of the hickory nuts to the image acquisition by the vision camera 220, the collaboration between the control mechanism and the management computer to analyze and classify defects, and finally the hickory nuts are moved to the corresponding station of the target sorting box 240. The control mechanism starts the high-pressure air pump 266 to blow them into the sorting box 240 for collection. The industrial control software installed on the management computer sets multiple standards such as "no defects", "minor cracks", "serious cracks", and "hollow". When the vision detection shows that the length of the crack in the hickory nut is large, the control mechanism determines it and triggers the corresponding high-pressure air pump 266 to start when it moves to the preset sorting box 240.

[0035] As a preferred technical solution, the visual inspection mechanism collects images of the walnuts. During the rotation of the sorting roller 260, the visual camera 220 collects images of the walnut surface from multiple angles to obtain complete surface information. Image recognition algorithms are used to detect the size of cracks on the surface of walnuts and to determine the grade of walnuts based on the severity of the defects.

[0036] During the rotation of the sorting roller 260, the vision camera 220 acquires images of the walnut surface from multiple angles, including the top and sides, obtaining complete surface information. An image recognition algorithm is then used to extract and match features of cracks and other defects, determining the grade based on the defect area and depth. Multi-angle image acquisition eliminates blind spots in detection, achieving a defect recognition accuracy of over 95%. The algorithm adapts to different defect types, ensuring a unified grading standard.

[0037] As a preferred technical solution, the control of the high-pressure air pump 266 of the corresponding sorting roller 260 to start includes: when the sorting roller 260 moves to the sorting station, the power is supplied to the corresponding high-pressure air pump 266 through the contact between the electrical contact 232 and the conductive contact 263, and at the same time the high-pressure air pumps 266 in the two adjacent sorting rollers 260 are started to blow the walnuts out from the middle of the sorting roller 260.

[0038] When the sorting roller 260 moves to the sorting station corresponding to the target sorting box 240, the electrical contact 232 and the conductive contact 263 make contact and conduction. At the same time, the control mechanism starts the high-pressure air pump 266 in the sorting roller 260 and the adjacent sorting roller 260. The two sets of airflows are sprayed out from the inclined through holes 261 on both sides, forming a combined force to blow the walnut from the middle concave part of the sorting roller 260 into the target sorting box 240.

[0039] After the visual information acquired by the vision camera 220 is transmitted to the management computer and control mechanism, the management computer and control mechanism energizes the preset contact 232 based on the information processing results, while the other contact 232s are not energized. When the corresponding sorting roller 260 moves to the preset position, the contact 232 connects with the conductive contact 263, and the corresponding high-pressure air pump 266 starts working.

[0040] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of protection claimed by the present invention. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. An automated intelligent grading device for thin-shelled pecans, characterized in that, include: The transmission mechanism includes a conveyor roller for carrying walnuts and a first drive component for the motion of the driver. A visual inspection mechanism includes at least one visual camera disposed on one side of the transmission mechanism for acquiring images of the appearance of thin-shelled pecans to identify whether they are damaged. The sorting actuator includes multiple movable sorting rollers and a second drive assembly for moving the drive. The sorting roller has a cavity inside, and a high-pressure air pump is connected to one side of the cavity. The control mechanism is electrically connected to the vision camera and the high-pressure air pump, and is used to start the high-pressure air pump based on the vision analysis structure to blow the walnuts into the corresponding sorting box. The visual inspection mechanism is installed above one end of the sorting support frame near the transmission mechanism. The second drive assembly includes a transmission belt located in the middle of the sorting support frame. The sorting rollers are arranged on both sides of the transmission belt and move with the follower.

2. The automated intelligent grading equipment for thin-shelled pecans according to claim 1, characterized in that, A friction plate for rotating the sorting roller is fixedly installed in the middle of the sorting support frame. The rotating wheel is connected to the transmission belt. The rotating wheel drives the sorting roller to rotate on both sides of the transmission belt. When the transmission belt moves, the rotating wheel releases friction from the friction plate and rotates, driving the sorting roller to rotate.

3. The automated intelligent grading equipment for thin-shelled pecans according to claim 2, characterized in that, The end of the rotating wheel is connected to a universal connector. A transverse groove is opened inside the rotating wheel. The top of one end of the universal connector is placed inside the rotating wheel and is connected to the inner wall of the transverse groove by a spring. The outer diameter of the spring is smaller than the inner diameter of the transverse groove.

4. The automated intelligent grading equipment for thin-shelled pecans according to claim 3, characterized in that, The universal connector is fixedly connected to a hollow shaft at one end outside the rotating wheel. The hollow shaft is connected to the sorting roller, and the high-pressure air pump is placed inside the hollow shaft.

5. The automated intelligent grading equipment for thin-shelled pecans according to claim 3, characterized in that, A counterweight is rotatably arranged inside the sorting roller. An arc-shaped piece on one side of the counterweight extends into the hollow shaft. A gas guide groove for guiding gas is provided in the middle of the counterweight. The sorting roller is arranged in a shape that is concave in the middle and convex on both sides. The cavity inside the sorting roller is located near the high-pressure air pump. Multiple sets of inclined through holes are opened on the side wall of the sorting roller and communicate with the internal cavity.

6. The automated intelligent grading equipment for thin-shelled pecans according to claim 5, characterized in that, The control mechanism includes a conductive integrated cover, and a circuit board is disposed inside the conductive integrated cover; Electrical contacts are provided on the conductive integrated cover. Conductive contacts are provided on the outside of the hollow shaft. When the sorting roller moves to the sorting station, the electrical contacts and the conductive contacts make contact and conduct electricity to supply power to the high-pressure air pump.

7. A method for grading thin-shelled pecans, comprising grading using the automated intelligent grading equipment for thin-shelled pecans as described in claim 6, characterized in that... The method includes the following steps: S1. Connect the control terminal to the control mechanism in the grading equipment. The control terminal is used to receive detection data, set grading parameters and monitor the equipment operation status. The walnuts are transported to the sorting execution mechanism through the conveying mechanism. S2. During the transportation process, images of the walnuts are collected by a visual inspection mechanism; S3. The control mechanism analyzes the acquired images, identifies surface defects of the walnuts, and determines the grade of the walnuts; S4. When the walnuts move to the sorting station corresponding to the target sorting box, the control mechanism controls the high-pressure air pump in the corresponding sorting roller to start, blowing the walnuts into the target sorting box for grading.

8. The grading method for thin-shelled pecans according to claim 7, characterized in that, The visual inspection mechanism collects images of walnuts. During the rotation of the sorting roller, the visual camera collects images of the walnut surface from multiple angles to obtain complete surface information. Image recognition algorithms are used to detect cracks, mold, and insect defects on the surface of walnuts, and the grade of walnuts is determined based on the severity of the defects.

9. The grading method for thin-shelled pecans according to claim 8, characterized in that, The control of the high-pressure air pump starting of the corresponding sorting roller includes: when the sorting roller moves to the sorting station, the power is supplied to the corresponding high-pressure air pump through the contact between the electrical contact and the conductive contact, and at the same time the high-pressure air pumps in the two adjacent sorting rollers are started to blow the walnuts out from the middle of the sorting roller.

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