Streamline sorting method

Abstract

The invention discloses a streamline sorting method. The method comprises the following steps: when a to-be-tested carrier enters a production streamline, allocating a target station identifier to the to-be-tested carrier based on a preset allocation strategy; in the process that the to-be-tested carrier moves on the production streamline, actual position information of the to-be-tested carrier is determined, and virtual position information associated with the to-be-tested carrier is synchronously updated in a control program according to the actual position information; and when the virtual position information is updated to a first station, controlling the first station to execute a corresponding sorting action on the to-be-tested carrier according to a matching relationship between the target station identifier and the station identifier of the first station. According to the method, through combination of two characteristics of information pre-binding and virtual position synchronization, a system can predict a carrier path in advance, non-stop straight-through of a non-target carrier is realized, and the overall sorting efficiency and the system throughput are improved.

Description

Technical Field

[0001] This invention relates to the field of automation control technology, and in particular to a streamlined sorting method. Background Technology

[0002] In industrial production, especially in high-precision manufacturing processes such as module testing, the efficient and accurate sorting and delivery of modules to be tested to the corresponding testing stations is crucial to overall production efficiency. Currently, this process widely adopts a centrally controlled sorting solution based on barcode scanner queries. Specifically, the carriers carrying the modules are transported along the assembly line. At each sorting node, they must come to a complete stop, and a barcode scanner reads the identification mark (such as a QR code) on the carrier. The control system then communicates and queries this mark with the background database in real time. Based on the returned carrier status (such as "tested" or "not tested"), it determines whether the current sorting node should intercept the carrier.

[0003] However, this sorting decision-making heavily relies on a sequential process of "stop-scan-central query-response." This means that even vehicles that have already been tested and do not require processing at the current node, or vehicles destined for downstream workstations, must undergo the same stop and query process at every sorting point they pass through. This "one-size-fits-all" approach leads to numerous unnecessary pauses and waits, creating a difficult-to-break upper limit on the flow rate and becoming a major obstacle to improving the overall production cycle time.

[0004] Furthermore, the highly centralized architecture of this solution also presents stability challenges. The response speed and reliability of the sorting system are largely constrained by the barcode scanner's recognition efficiency, network communication latency, and the query performance of the central database. Any delay or failure in any link will directly cause production line blockage or even shutdown. At the same time, frequent database query operations also place unnecessary load on the system server. Summary of the Invention

[0005] One of the objectives of this invention is to provide a streamlined sorting method to solve the technical problems of low processing efficiency and long response time caused by the over-reliance on identification devices at sorting points to suspend and detect passing vehicles in sequence.

[0006] One objective of this invention is to provide a streamlined sorting method, comprising: when a test vehicle enters the production line, assigning a target workstation identifier to the test vehicle based on a preset allocation strategy; determining the actual position information of the test vehicle as it moves on the production line, and synchronously updating virtual position information associated with the test vehicle in a control program according to the actual position information; when the virtual position information is updated to a first workstation, controlling the first workstation to perform a corresponding sorting action on the test vehicle according to the matching relationship between the target workstation identifier and the workstation identifier of the first workstation.

[0007] As a further improvement of one embodiment of the present invention, the step of assigning a target workstation identifier to the test vehicle based on a preset allocation strategy when the test vehicle enters the production line includes: acquiring the status information of several test units on the production line, wherein the status information represents at least one operating indicator of the operating status of each test unit; and assigning a target workstation identifier to the test vehicle based on the status information and the preset allocation strategy.

[0008] As a further improvement of one embodiment of the present invention, the step of assigning a target workstation identifier to the test vehicle based on the status information and a preset allocation strategy includes: responding to the material feeding request of several test units, counting the total number of vehicles that have completed testing of several test units within a unit time; and determining the target workstation identifier of the test vehicle based on the minimum total number of test units.

[0009] As a further improvement of one embodiment of the present invention, the step of assigning a target workstation identifier to the test vehicle based on the status information and a preset allocation strategy includes: responding to the material feeding request of a plurality of test units, calculating the historical test yield of the plurality of test units within a unit time; and determining the target workstation identifier of the test vehicle based on the test unit with the highest historical test yield.

[0010] As a further improvement of one embodiment of the present invention, the step of assigning a target station identifier to the test vehicle based on the status information and a preset allocation strategy includes: in response to the feeding request of several test units, determining the distance of each test unit from the feeding position; and determining the target station identifier of the test vehicle based on the test unit with the smallest distance.

[0011] As a further improvement of one embodiment of the present invention, the step of assigning a target workstation identifier to the test vehicle based on the status information and a preset allocation strategy includes: in response to the feeding request of several test units, determining the corresponding waiting time for feeding; and determining the target workstation identifier of the test vehicle based on the test unit with the maximum waiting time for feeding.

[0012] As a further improvement of one embodiment of the present invention, multiple position sensors are provided on the production line; the step of determining the actual position information of the sensor and synchronously updating the virtual position information associated with the test vehicle in the control program according to the actual position information includes: allocating a virtual storage area for the position sensors on the production line; responding to the test vehicle triggering a position sensor, updating the virtual position information associated with the test vehicle based on the detection result of the position sensor, and updating the target workstation identifier of the test vehicle to the virtual storage area.

[0013] As a further improvement of one embodiment of the present invention, a first position sensor and a second position sensor are sequentially arranged in the moving direction of the production line; the step of responding to the triggering of a position sensor by the test vehicle, updating the virtual position information associated with the test vehicle based on the detection result of the position sensor, and updating the target workstation identifier of the test vehicle to the virtual storage area includes: when the first position sensor detects that the test vehicle leaves its detection area, and the second position sensor detects that the test vehicle enters its detection area, the target workstation identifier is transferred from the first virtual storage area corresponding to the first position sensor to the second virtual storage area corresponding to the second position sensor.

[0014] As a further improvement of one embodiment of the present invention, the step of controlling the first station to perform a corresponding sorting action on the carrier under test based on the matching relationship between the target station identifier and the station identifier of the first station includes: determining whether the target station identifier matches the station identifier of the first station; if yes, controlling the first station to intercept the carrier under test and process it; if no, controlling the first station to directly release the carrier under test so that it can continue to flow to the next station.

[0015] As a further improvement of one embodiment of the present invention, the processing includes: controlling the first workstation to obtain the identification of the vehicle under test, and determining whether the identification is consistent with the target workstation identification; if yes, controlling the vehicle under test to enter the test unit of the first workstation; if no, triggering an abnormal alarm or releasing the vehicle.

[0016] Compared with the prior art, the embodiments of the present invention have at least one of the following beneficial effects: This invention employs a streamlined sorting method. By assigning a target workstation identifier when a vehicle enters the streamline, it assigns a routing instruction to the vehicle throughout its entire flow cycle, achieving pre-binding of information and eliminating reliance on real-time queries. Then, based on the vehicle's actual location information, the corresponding virtual location information is synchronously updated. A virtual location that moves synchronously with the physical vehicle is constructed in the control program, allowing its target identifier to be transferred as an intrinsic attribute with physical movement. When the virtual location arrives at a workstation, a decision is made by directly comparing the existing local target identifier with the workstation identifier. This method, through the combination of "pre-binding of information" and "synchronization of virtual location," enables the system to predict vehicle paths in advance, allowing non-target vehicles to pass through without interruption, thus improving overall sorting efficiency and system throughput. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the principle of a streamlined sorting system according to one embodiment of the present invention.

[0018] Figure 2 This is a schematic diagram of the process sorting system in one embodiment of the present invention.

[0019] Figure 3 This is a schematic diagram of the steps of a streamlined sorting method in one embodiment of the present invention.

[0020] Figure 4 This is a schematic diagram of the production flow line in one embodiment of the present invention.

[0021] Figure 5 This is a schematic diagram of step S1 in one embodiment of the present invention.

[0022] Figure 6(a) is a schematic diagram of step S12 in a specific embodiment of the present invention.

[0023] Figure 6(b) is a schematic diagram of step S12 in another specific embodiment of the present invention.

[0024] Figure 6(c) is a schematic diagram of step S12 in another specific embodiment of the present invention.

[0025] Figure 6(d) is a schematic diagram of step S12 in another specific embodiment of the present invention.

[0026] Figure 7 This is a schematic diagram of step S2 in one embodiment of the present invention.

[0027] Figure 8 This is a schematic diagram of step S3 in one embodiment of the present invention.

[0028] Figure 9This is a flowchart illustrating the streamlined sorting method in a preferred embodiment of the present invention. Detailed Implementation

[0029] The present invention will now be described in detail with reference to the specific embodiments shown in the accompanying drawings. However, these embodiments do not limit the present invention, and any structural, methodological, or functional modifications made by those skilled in the art based on these embodiments are included within the scope of protection of the present invention.

[0030] It should be noted that the term "comprising" or any other variations thereof is intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. In the description of specific embodiments of the invention, terms such as "upper," "lower," and "vertical" indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, generally with reference to the device or apparatus in its normal operating state, and do not indicate that the indicated position or element must have a specific orientation. Furthermore, terms such as "first," "second," and "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0031] like Figure 1 As shown, one embodiment of the present invention provides a streamlined sorting system 100.

[0032] The streamlined sorting system 100 is a system for automatically sorting carriers moving along a production line. It is a device composed of both hardware and software. For example, on an electronic product assembly production line, this sorting system is used to sort carriers carrying electronic components so that components of different types or at different stages of production can be transferred to corresponding workstations for further processing.

[0033] Specifically, such as Figure 2 As shown, the sorting system 100 physically comprises a continuous production flow line that sequentially connects a loading buffer, at least one sorting processing unit (e.g., Unit 1, Unit 2, and Unit 3), and an unloading buffer. Each sorting processing unit integrates multiple test units, such as Test Unit 1, Test Unit 2, Test Unit 3, Test Unit 4, Test Unit 5, and Test Unit 6.

[0034] In one specific embodiment, the sorting system 100 is logically controlled by a programmable logic controller (PLC), which is connected to the execution components of the entire sorting system 100 through its input / output modules.

[0035] The sorting system 100 includes a first binding module 11, which is used to assign a target workstation identifier to the carrier under test based on a preset allocation strategy when the carrier under test enters the production line.

[0036] Specifically, the barcode scanner configured in the loading buffer works in conjunction with the PLC. When the carrier under test enters the loading buffer and triggers the block entry sensor installed therein, the scanner reads the carrier's identity information, and the PLC runs the allocation strategy program stored inside it. Based on the real-time status information of each test unit (such as workload, yield, etc.), it calculates the optimal target station and generates a target station identifier.

[0037] The sorting system 100 includes a second binding module 12, which is used to determine the actual position information of the carrier under test during its movement on the production line, and to synchronously update the virtual position information associated with the carrier under test in the control program based on the actual position information.

[0038] Specifically, the actual position information of the test vehicle is determined by multiple position sensors (such as photoelectric sensors, magnetic sensors, etc.) arranged on the production line. These sensors can sense the position changes of the test vehicle in real time and transmit the relevant information to the second binding module 12.

[0039] The sorting system 100 includes a processing module 13. The processing module 13 is used to control the first station to perform corresponding sorting actions on the carrier under test according to the matching relationship between the target station identifier and the station identifier of the first station when the virtual location information is updated to the first station.

[0040] Specifically, at the decision point of the sorting unit (e.g., when the product detection sensor is triggered), the PLC calls its internal matching judgment program. This program reads the target station identifier and compares it with the station identifier of this sorting unit. Based on the comparison result, the PLC's output module drives the actuators of the sorting unit (such as blocking cylinders, lifting cylinders, steering mechanisms, etc.) to move. If a match is found, the test vehicle is intercepted and guided into the test unit; if a mismatch is found, the system maintains a release state, allowing the test vehicle to pass directly through this sorting unit. Finally, the test vehicle that has completed testing or transfer is transported to the unloading buffer, its virtual position information is cleared, and the system prepares to process the next test vehicle.

[0041] like Figure 3 As shown, one embodiment of the present invention provides a streamlined sorting method.

[0042] The streamlined sorting method is applied to a streamlined sorting system.

[0043] In one embodiment, the streamlined sorting system can be as follows: Figure 1and Figure 2 The configuration described above is applied, and the corresponding technical solutions are referenced in the sorting method provided by this invention.

[0044] Of course, the streamlined sorting system applied to the streamlined sorting method provided by the present invention is not limited to this configuration structure. For example, the first binding module 11 and the second binding module 12 can be integrated into one module, which has the functions of both binding modules at the same time.

[0045] like Figure 3 As shown, a streamlined sorting method provided in one embodiment of the present invention includes the following steps.

[0046] Step S1: When the test vehicle enters the production line, a target workstation identifier is assigned to the test vehicle based on a preset allocation strategy. Step S2: During the process of the test vehicle moving on the production line, determine its actual position information, and based on the actual position information, synchronously update the virtual position information associated with the test vehicle in the control program. Step S3: When the virtual location information is updated to the first workstation, the first workstation is controlled to perform the corresponding sorting action on the test vehicle according to the matching relationship between the target workstation identifier and the workstation identifier of the first workstation.

[0047] In this way, by assigning target station identifiers when the vehicle enters the flow line, the vehicle under test is given routing instructions that run through its entire flow cycle, realizing the pre-binding of information and eliminating the dependence on real-time queries; then, based on the actual position information of the vehicle, the corresponding virtual position information is updated synchronously, and a virtual position that moves synchronously with the physical vehicle is constructed in the control program, so that its target identifier can be transmitted as an intrinsic attribute with the physical movement; and when the virtual position arrives at a certain station, a decision can be made by directly comparing the existing target identifier with the station identifier locally.

[0048] This method combines the features of "information pre-binding" and "virtual location synchronization" to enable the system to predict vehicle paths in advance, allowing non-target vehicles to pass through without interruption, thereby improving overall sorting efficiency and system throughput.

[0049] In step S1, the test carrier refers to the material carrier that carries the product or module to be tested. It has a unique identifier (e.g., a QR code) and can move on a streamlined transmission device (such as a belt, roller, etc.). It is the physical object that is tracked and processed throughout the entire process.

[0050] A production line refers to an automated material handling system that connects multiple units such as loading, sorting, testing, and unloading into a continuous physical path, along which the test vehicle is transported in an orderly manner.

[0051] For example, such as Figure 4 As shown, the production line includes three unit conveyor belts (Unit1 Belt, Unit2 Belt and Unit3 Belt), which constitute the main channel for vehicle transportation and connect various functional modules. Multiple sorting units can be set on each unit conveyor belt. For example, each unit conveyor belt is equipped with one sorting unit, namely Unit1 sorting unit, Unit2 sorting unit and Unit3 sorting unit.

[0052] In addition, each sorting unit includes a blocking cylinder, a lifting cylinder, and a stopping cylinder. The blocking cylinder is located at the entrance of the sorting unit and is used to intercept or release the carrier to be tested; the lifting cylinder is used to lift the carrier to be tested and subsequently transfer it into the test unit; the stopping cylinder is located at the exit of the sorting unit and is used to control the flow direction of the carrier to be tested. Multiple sensors (such as U1 feed sensor 1, U1 feed sensor 2, and U1 discharge sensor) are installed in each sorting unit to expand the monitoring range.

[0053] The production line also includes a loading buffer and a unloading buffer. The loading buffer is the starting point of the production line and is equipped with an inlet sensor to detect whether a carrier has entered the production line and is in place, triggering the identification registration and target station allocation process for the carrier under test. The unloading buffer is the ending point of the production line and is equipped with a blocking cylinder and inlet / outlet sensors. The inlet / outlet sensors are used to confirm that the carrier under test has completely entered or left the buffer and to activate the blocking cylinder to lock or release the carrier's position, while simultaneously feeding back the current occupancy status of the buffer to the PLC.

[0054] The target workstation identifier is the output of the allocation strategy; it can be a number, a code, or an address. In the PLC control program, it uniquely represents a specific, final test location (e.g., "Unit 2" or "Workstation A"). It can be a single test unit or a specific test workstation; there are no specific restrictions.

[0055] Furthermore, assigning it to the vehicle under test means that the target workstation identifier is an inherent attribute of the vehicle, and it is bound to the physical vehicle. At this point, the vehicle under test is no longer a "blind package" being pushed, but an "intelligent task unit" with a clear destination that can be tracked and predicted.

[0056] like Figure 5 As shown, in one embodiment, step S1 may specifically include the following steps.

[0057] Step S11: Obtain the status information of several test units on the production line, wherein the status information represents at least one operating indicator of the operating status of each test unit. Step S12: Based on the status information and the preset allocation strategy, assign a target workstation identifier to the vehicle under test.

[0058] In this way, by introducing status information as a decision input, the allocation of target workstations is no longer fixed or random, but can be adaptively adjusted according to multiple quantitative indicators of each test unit, thereby achieving optimal allocation of production resources from the source and improving overall efficiency.

[0059] In step S11, a test unit refers to an independent automated unit on the production line that has complete testing functions. It can be understood as a "fully functional test station" and may include test equipment, sorting mechanisms (such as lifting, rotating, and translating mechanisms, where the load connects the test vehicle to or from the test equipment), local sensors, and interfaces for communication with the PLC.

[0060] For example, such as Figure 2 As shown, there are six test units on the production line: test unit 1 to test unit 6. The allocation strategy is to select one of these six test units as the final moving target of the vehicle under test.

[0061] In step S12, the status information refers to the dynamically changing quantitative data collected from the test unit that reflects its current working status and capabilities.

[0062] Furthermore, the allocation strategy refers to a set of pre-defined rules or algorithms used for decision-making. Its purpose is to select an optimal target for the currently entering test vehicle among multiple available test units. In this invention, load balancing strategies, quality-first strategies, proximity-based allocation strategies, or waiting time strategies can be used to determine the target workstation identifier.

[0063] As shown in Figure 6(a), in one specific embodiment, step S12 specifically includes the following steps.

[0064] Step S1211: In response to the material feeding request of several test units, count the total number of several carriers that have completed testing of several test units within a unit time. Step S1212: Based on the minimum total number of test units, determine the target workstation identifier of the test unit.

[0065] In this way, by assigning new test tasks to the workstation with the fewest completed tasks, the test load is automatically balanced among the workstations, avoiding the production line bottleneck caused by the overload of individual workstations, thereby improving the overall throughput of the production line.

[0066] In step S1211, the unit of time can be a production shift (e.g., 8 hours) or a calendar day (24 hours), without specific restrictions. The PLC has an internal counter that accumulates the number of vehicle tests completed by each test unit within that time period.

[0067] Furthermore, the scope of this statistics and decision-making is a dynamic, requesting set of test units, ensuring the targeted and effective allocation of resources, assigning the test vehicles only to workstations that truly need them and are ready.

[0068] As shown in Figure 6(b), in one specific embodiment, step S12 specifically includes the following steps.

[0069] Step S1221: In response to the material feeding request of several test monomers, the historical test yield of the several test monomers is calculated within a unit time. Step S1222: Based on the test unit with the highest historical test yield, determine the target workstation identifier of the test vehicle.

[0070] In this way, by assigning new test tasks to the workstations with the highest historical yield, data-driven approaches are used to give the best-performing test equipment more production opportunities, thereby increasing the success rate of a single test in terms of probability and optimizing the overall product quality.

[0071] In step S1221, the historical test yield refers to the percentage of qualified products out of the total number of tests completed by the test unit over a past period. It is an indicator used to measure the working quality and stability of the test unit.

[0072] In one specific embodiment, a PLC control program is used to statistically analyze and maintain historical test yield rates. For example, each test unit (such as test unit 1) maintains a data record tracking its 100 most recently completed test tasks. If 98 of these tests are deemed "qualified," then the current "historical test yield rate" for that test unit is 98%.

[0073] As shown in Figure 6(c), in one specific embodiment, step S12 specifically includes the following steps.

[0074] Step S1231: In response to the feeding request of several test cells, determine the distance of each test cell from the feeding position; Step S1232: Based on the test unit with the minimum distance, determine the target workstation identifier of the vehicle under test.

[0075] In this way, by adopting a proximity allocation strategy, the physical path that the test vehicle needs to travel is directly shortened. This not only reduces the actual ineffective movement of the vehicle on the flow line and speeds up the arrival of the test vehicle at the work station, but also reduces operating energy consumption, achieving dual optimization of efficiency and cost.

[0076] As shown in Figure 6(d), in one specific embodiment, step S12 specifically includes the following steps.

[0077] Step S1211: In response to the feeding requests of several test monomers, determine their corresponding waiting time for feeding. Step S1212: Based on the test unit with the maximum waiting time for feeding, determine the target station identifier of the test vehicle.

[0078] In this way, by assigning new test tasks to the workstation with the longest waiting time, the long-term idleness of some workstations is effectively avoided, thereby maximizing the utilization rate of all test units.

[0079] In step S1211, the waiting time for material loading refers to the time interval from when a test unit completes its current task, prepares to receive a new carrier, and sends a material loading request signal to the PLC, until it is successfully assigned a new carrier. It is used as an indicator to measure the resource idleness and response fairness of the test unit.

[0080] In the PLC control program, a timer can be used to record the waiting time for material loading. When a test unit (such as test unit 2) sends a material loading request signal, the PLC or host computer starts a dedicated timer for that test unit, accumulating its waiting time in seconds or milliseconds. When the PLC or host computer responds to the request and assigns a target station identifier of a carrier to it, the timer stops counting, and its final timing result is the waiting time for material loading of that test unit.

[0081] like Figure 7 As shown, in one embodiment, multiple position sensors are set on the production line, and step S2 may specifically include the following steps.

[0082] Step S21: Allocate a virtual storage area for the position sensors on the production line; Step S22: In response to the vehicle under test triggering a position sensor, update the virtual position information associated with the vehicle under test based on the detection result of the position sensor, and update the target workstation identifier of the vehicle under test to the virtual storage area.

[0083] In this way, by solidifying the flowing physical carrier into a data object that can be stably tracked and addressed within the controller, a clear data base point is provided for the sorting operation.

[0084] In step S21, the detection result of the position sensor is the actual position information of the carrier under test moving on the production line, such as "located at the entrance of sorting unit Unit1".

[0085] In one specific embodiment, the position sensor may be a distance switch, a photoelectric sensor, or a vision sensor (such as a camera), and there are no restrictions on the type.

[0086] In step S22, virtual location information refers to creating a location in the digital world of the control program (such as the memory of the PLC) that corresponds one-to-one with the physical vehicle. It is a mapping and abstraction of the actual location information.

[0087] In addition, the "allocation" in step S21 can be understood as building a parallel coordinate framework with the same structure for the physical world (i.e., the movement of the vehicle under test on the production line) in the digital world (i.e., the PLC control program), so that each physical location has a unique address (virtual storage area) in the PLC.

[0088] In step S22, "response and update" can be understood as any displacement event of the test vehicle on the production line (triggering the position sensor) will drive a data write operation in the PLC control program, storing the target station identifier representing the vehicle's identity in the corresponding virtual storage area. This mechanism ensures that the virtual position information of the vehicle is always consistent with its actual physical position, allowing the PLC to obtain information such as the test vehicle information and the target station identifier at any time by querying the local virtual storage area rather than the central database.

[0089] In one specific embodiment, a first position sensor and a second position sensor are sequentially arranged in the moving direction of the production line, and step S22 may specifically include the following steps.

[0090] Step S22': When the first position sensor detects that the test vehicle leaves its detection area and the second position sensor detects that the test vehicle enters its detection area, the target workstation identifier is transferred from the first virtual storage area corresponding to the first position sensor to the second virtual storage area corresponding to the second position sensor.

[0091] In this way, by combining the events of two adjacent sensors ("departure" and "entry") into an indivisible complete transaction, the abnormal state of the actual position information of the vehicle under test corresponding to the virtual position information in the control program appearing in two positions at the same time or disappearing completely is avoided, ensuring that the actual movement path of the vehicle is strictly synchronized with the virtual movement path in the control program.

[0092] Specifically, for each physical location on the flow line (such as the entrance, lifting position, and exit of a Unit), the PLC control program assigns a corresponding "state." Each state defines its preconditions, the action to be performed, and the next state. When a position sensor A is triggered during the movement of the test vehicle, the corresponding logic in the control program may switch from "state 1" to "state 2." At the same time, the control program moves the "target station identifier" from the virtual storage area representing "state 1" to the virtual storage area representing "state 2."

[0093] Similarly, when a position sensor B is triggered during the movement of the test vehicle, the corresponding logic in the control program may switch from "state 2" to "state 3". At this time, the control program will also move the "target workstation identifier" to the virtual storage area representing "state 3".

[0094] It should be noted that when a vehicle moves along a flow line, its virtual position information and target station identifier will be transferred between virtual storage areas (such as registers) corresponding to the physical sensors within the control program. For example, when a vehicle moves from the detection area of ​​sensor 1 to the detection area of ​​sensor 2, the system will transfer the information in the virtual storage area of ​​sensor 1 to the virtual storage area of ​​sensor 2, while clearing the original information in the storage area of ​​sensor 1 to ensure that the storage area can be reused by subsequent vehicles.

[0095] like Figure 8 As shown, in one embodiment, step S3 specifically includes the following steps.

[0096] Step S31: Determine whether the target workstation identifier matches the workstation identifier of the first workstation; If so, proceed to step S32A, and control the first station to intercept the vehicle under test and process it; If not, proceed to step S32B and control the first station to directly release the test vehicle so that it can continue to flow to the next station.

[0097] In this way, the sorting action can be precisely triggered and non-target vehicles can move freely without obstruction, eliminating unnecessary delays in the sorting process.

[0098] In step S31, the first station refers to any sorting and processing unit on the production line.

[0099] In one specific embodiment, the "processing it" step S32A specifically includes the following steps.

[0100] Step S32A1: Control the first workstation to obtain the identity identifier of the vehicle under test, and determine whether the identity identifier is consistent with the target workstation identifier; If so, then in step S32A2, control the test vehicle to enter the test unit of the first station; If not, proceed to step S32A3 to trigger an abnormal alarm or allow passage.

[0101] In this way, by using the first workstation to intercept the vehicle to be tested and scanning its code for secondary confirmation, it is ensured that the vehicle is a legitimate vehicle that has not been tested. Then, the sorting execution mechanism is controlled to transfer it to its corresponding test unit, ensuring the accuracy and reliability of the test.

[0102] Specifically, each process state in the system has a preset execution time limit. When the control program switches to a new process state, the motor starts normally, driving the carrier to run. At this time, the corresponding sensors should produce the expected state change. If the sensor feedback is abnormal due to equipment failure or signal interference, the control program will not be able to receive the correct signal within the set time window, thereby triggering a timeout alarm, indicating that the current process state is abnormal, so as to facilitate timely investigation of the cause.

[0103] To ensure consistency between data streams and physical streams, the system implements a dynamic binding and verification mechanism for vehicle information and sensor status. Throughout the entire flow of vehicle information, if the system detects a mismatch between the vehicle information tracked in the program and the binding status actually reported by the physical sensor, an alarm will be generated immediately. At the same time, manual confirmation of the cause of the anomaly is required, and the relevant information in the control program will be cleared if the conditions are met.

[0104] In addition, considering the flexibility requirements of the production site, when a moving vehicle needs to be manually removed for any reason, the operator can use the "one-click removal" function on the operation interface to safely clear its binding information in the control program after confirming that the physical vehicle has been removed (the corresponding sensor can no longer detect it), thereby maintaining the consistency between virtual information and physical reality.

[0105] Figure 9 A flowchart illustrating the sorting method of the present invention in a preferred embodiment is shown below. Figure 4 and Figure 9 The working process of the sorting method described in this invention is described.

[0106] After the sorting system (e.g., PLC) starts, it enters a standby state. When the InBlock sensor in the loading buffer detects that a test carrier has entered, and the system receives a loading request from a downstream test unit, the system assigns a target station identifier to the current carrier according to a preset allocation strategy. For example, if the strategy determines that the carrier needs to be sent to test unit 2 in Unit 1, then the target identifier "2" is bound to the carrier, completing the carrier's identity information registration and binding. Subsequently, the conveyor belt starts, and the carrier begins to move forward along the flow line.

[0107] During the carrier transfer process, multiple sensors distributed along the flow line continuously monitor the real-time position of the carrier. When the carrier triggers the In1 feed sensor of Unit1, the control program, based on the detection result, transfers the target station identifier of the carrier from its currently associated InBlock area to the Unit_In1 area corresponding to the In1 sensor, thereby synchronously updating the virtual position of the carrier.

[0108] As the vehicle continues to move and successively triggers subsequent sensors such as the product detection sensor PdtCheck, the target identifier "2" will be sequentially passed between the corresponding storage areas within the control program, thereby ensuring that the actual movement path of the vehicle remains consistent with its virtual path in real time.

[0109] When the virtual location information is updated to the decision point corresponding to the Unit sorting unit, the control program immediately executes the sorting decision logic, reads the target workstation identifier "2" stored locally and compares it with the workstation identifier of Unit 1. Since the two match, the control program first triggers barcode scanning for verification. After confirming that the carrier is a valid untested carrier, it randomly controls the sorting mechanism of Unit 1, such as the lifting cylinder and rotating cylinder, to transfer the carrier to the test unit 2.

[0110] If the target identifier does not match the current unit, the control actuator maintains the release state, allowing the vehicle to pass through the unit without intervention and continue to subsequent processing stages such as Unit 2 sorting unit. Finally, the vehicle that has completed testing or the entire flow is transported to the unloading buffer, its binding information is cleared, and the system prepares for the next work cycle. If any timeout or abnormal sensor signal occurs at any stage of the process, the system will immediately trigger an alarm and record the fault status.

[0111] The control method described in this invention has the following advantages: First, by pre-binding the target workstation identifier to the vehicle and transmitting it synchronously with physical movement, the sorting decision is localized. This allows non-target vehicles to be released directly without stopping the central query when passing through the workstation, eliminating the efficiency bottleneck caused by the traditional barcode query method and improving the overall throughput and response speed of the system.

[0112] Secondly, based on the real-time perception of the vehicle's position by the sensor network and the precise mapping of the virtual path within the program, an environment with a high degree of consistency between physical flow and logical control is constructed. This not only provides accurate and reliable basis for sorting decisions, but also enables visual tracking of the vehicle throughout the process, as well as intelligent fault tolerance and rapid recovery from physical anomalies, thereby enhancing the reliability and robustness of the system.

[0113] In summary, the streamline sorting method provided by this invention assigns a target workstation identifier when the vehicle enters the streamline, giving the vehicle a routing instruction that runs through its entire flow cycle, thus achieving pre-binding of information and eliminating reliance on real-time queries. Then, based on the actual position information of the vehicle, the corresponding virtual position information is synchronously updated. A virtual position that moves synchronously with the physical vehicle is constructed in the control program, allowing its target identifier to be transmitted as an intrinsic attribute with the physical vehicle's movement. When the virtual position arrives at a workstation, a decision is made by directly comparing the existing target identifier with the workstation identifier. This method, through the combination of "pre-binding of information" and "synchronization of virtual position," enables the system to predict the vehicle path in advance, allowing non-target vehicles to pass through without interruption, improving overall sorting efficiency and system throughput.

[0114] It should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This way of describing the specification is only for clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

[0115] The detailed descriptions listed above are merely specific descriptions of feasible embodiments of the present invention, and are not intended to limit the scope of protection of the present invention. All equivalent embodiments or modifications made without departing from the spirit of the present invention should be included within the scope of protection of the present invention.

Claims

1. A flowline sorting method, characterized by, The application comprises the following steps: When a test carrier enters a production line, a target station identifier is assigned to the test carrier based on a preset assignment strategy; During the movement of the test carrier on the production line, actual position information of the test carrier is determined, and virtual position information associated with the test carrier is updated in a control program synchronously according to the actual position information; When the virtual position information is updated to a first station, a corresponding sorting action is performed on the test carrier by the first station according to a matching relationship between the target station identifier and a station identifier of the first station.

2. The sorting method according to claim 1, characterized in that, The step of assigning a target station identifier to the test carrier based on a preset assignment strategy when a test carrier enters a production line comprises the following steps: Obtaining state information of a plurality of test units on the production line, the state information representing at least one running index of the running state of each test unit; Based on the state information and a preset assignment strategy, a target station identifier is assigned to the test carrier.

3. The sorting method according to claim 2, characterized in that, The step of assigning a target station identifier to the test carrier based on the state information and a preset assignment strategy comprises the following steps: In response to the feeding request of a plurality of test units, the total number of test carriers that have completed testing within a unit time is counted; Based on the test unit with the minimum total number of test carriers, a target station identifier of the test carrier is determined.

4. The sorting method according to claim 2, characterized in that, The step of assigning a target station identifier to the test carrier based on the state information and a preset assignment strategy comprises the following steps: In response to the feeding request of a plurality of test units, the historical test yield of the plurality of test units within a unit time is counted; Based on the test unit with the maximum historical test yield, a target station identifier of the test carrier is determined.

5. The sorting method according to claim 2, characterized in that, The step of assigning a target station identifier to the test carrier based on the state information and a preset assignment strategy comprises the following steps: In response to the feeding request of a plurality of test units, the distance of each test unit from a feeding position is determined; Based on the test unit with the minimum distance, a target station identifier of the test carrier is determined.

6. The sorting method according to claim 2, characterized in that, The step of assigning a target station identifier to the test carrier based on the state information and a preset assignment strategy comprises the following steps: In response to the feeding request of a plurality of test units, the waiting feeding time length corresponding to each test unit is determined; Based on the test unit with the maximum waiting feeding time length, a target station identifier of the test carrier is determined.

7. The sorting method according to claim 1, characterized in that, A plurality of position sensors are arranged on the production line; the step of determining actual position information of the test carrier and updating virtual position information associated with the test carrier in a control program synchronously according to the actual position information comprises the following steps: A virtual storage area is assigned to the position sensors on the production line; In response to the test carrier triggering a position sensor, the virtual position information associated with the test carrier is updated based on the detection result of the position sensor, and the target station identifier of the test carrier is updated to the virtual storage area.

8. The sorting method according to claim 7, characterized in that, The first position sensor and the second position sensor are arranged in sequence in the moving direction of the production line; the position sensor is triggered in response to the to-be-tested carrier, the virtual position information associated with the to-be-tested carrier is updated based on the detection result of the position sensor, and the target station identifier of the to-be-tested carrier is updated to the virtual storage area, including: When the first position sensor detects that the to-be-tested carrier leaves the detection area thereof, and the second position sensor detects that the to-be-tested carrier enters the detection area thereof, the target station identifier is transferred from the first virtual storage area corresponding to the first position sensor to the second virtual storage area corresponding to the second position sensor.

9. The sorting method according to claim 1, characterized in that, The control of the first station on the to-be-tested carrier to perform a corresponding sorting action according to the matching relationship between the target station identifier and the station identifier of the first station, including: determining whether the target station identifier matches the station identifier of the first station; if yes, controlling the first station to intercept the to-be-tested carrier and processing the same; if no, controlling the first station to directly release the to-be-tested carrier to continue to flow to the next station.

10. The sorting method according to claim 9, characterized in that, The processing, including: controlling the first station to acquire the identity identifier of the to-be-tested carrier, and determining whether the identity identifier is consistent with the target station identifier; if yes, controlling the to-be-tested carrier to enter the test unit of the first station; if no, triggering an abnormal alarm or release.

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