Intelligent loading, unloading and sorting device based on AI vision

Abstract

The invention relates to an intelligent loading, unloading and sorting device based on AI vision, and relates to the technical field of logistics sorting and visual inspection, the device comprises an input conveying table, a detection table, a waste collection table, an output conveying table, a clamp frame and a main controller; a conveying clamp capable of moving in multiple dimensions is arranged on the clamp frame and is used for transferring packages among the stations; a detection sleeve with a visual detection piece is arranged on the detection table, and is matched with the light supplementing system to realize AI visual detection of the whole surface of the package; the waste collecting table is of a relay type collecting structure, and continuous waste collection is guaranteed. According to the method, through full-automatic closed-loop design of'detection-decision-execution ', traditional manual operation is replaced, and the detection and sorting efficiency and precision are improved; the integrated structure reduces the equipment cost and the maintenance difficulty; and the adaptability and the operation stability of equipment are improved through the adjustable clamping structure and the continuous operation design, and the device is suitable for parcel detecting and sorting operation in the food supply chain and the logistics transportation industry and has remarkable practical value.

Description

Technical Field

[0001] This application relates to the field of logistics sorting and visual inspection technology, and in particular to an intelligent loading and unloading and sorting device based on AI vision. Background Technology

[0002] In the food supply chain and logistics industry, the inspection of the appearance integrity of packages is a crucial step in ensuring food quality and safety as well as the quality of logistics services. Key inspection indicators include the presence of defects such as stains, damage, inadequate sealing, and deformation on the package surface. Currently, the industry still largely relies on manual labor for detecting these package defects. This involves quality inspectors visually observing and manually checking each package while simultaneously loading, unloading, and sorting them.

[0003] However, with the explosive growth of the e-commerce industry and the global expansion of the food supply chain, the volume of logistics parcels has increased exponentially. Traditional manual inspection and sorting methods are no longer sufficient to meet the industry's development needs, gradually exposing many significant technical shortcomings. Firstly, inspection efficiency is low. Manual inspection speed is limited by physiological limits, making it difficult to match the high-speed operation of modern logistics production lines. This often leads to parcel backlogs, hindering overall logistics turnover efficiency, especially during peak business periods such as e-commerce promotions. Secondly, inspection accuracy is unstable. Manual inspection is susceptible to factors such as visual fatigue, subjective experience differences, and lighting conditions, resulting in insufficient ability to identify minor defects such as small breaks and slight stains. The rates of missed detections and false detections are high. Minor damage to food parcels can lead to internal food contamination and spoilage, directly posing food safety risks and harming consumer rights and corporate brand reputation. Thirdly, overall operating costs are high. To meet inspection demands, companies need to maintain a large number of quality inspectors, incurring high labor costs and training expenses. Furthermore, manual sorting has a high mis-sorting rate, requiring additional costs for subsequent error correction and cargo traceability. Summary of the Invention

[0004] To improve the situation in the above-mentioned technologies, this application provides an intelligent loading, unloading and sorting device based on AI vision.

[0005] The intelligent loading, unloading, and sorting device based on AI vision provided in this application adopts the following technical solution: An AI vision-based intelligent loading, unloading, and sorting device includes an input conveyor for docking and conveying packages to be sorted; an inspection station equipped with visual inspection devices for inspecting the packages; a waste collection station for receiving packages that fail inspection; an output conveyor for receiving and conveying packages that pass inspection; and a clamping frame with a movably mounted conveyor clamp for holding and fixing the packages. The clamping frame is equipped with a horizontal drive module and a vertical drive module. The horizontal drive module drives the conveyor clamp to reciprocate above the input conveyor, inspection station, waste collection station, and output conveyor, while the vertical drive module drives the conveyor clamp to reciprocate vertically.

[0006] By adopting the above technical solution, firstly, the packages to be sorted are automatically fed into the working range of the device via the input conveyor. Then, the horizontal and vertical drive modules work in precision to drive the conveyor gripper to grab the package and accurately transfer it to the inspection table. After that, the vision inspection device on the inspection table performs image acquisition and AI analysis on the package. After the inspection result is generated, the system controller immediately makes a decision: if the package is unqualified, the drive module controls the conveyor gripper to transfer and release it to the waste collection table to achieve automatic rejection; if the package is qualified, it is transferred to the output conveyor to enter the next process.

[0007] The technical solution involved in this application constructs an integrated device consisting of an input conveyor, an inspection station, an inspection station with visual inspection components, a waste collection station, an output conveyor, and a multi-dimensional movable conveying fixture. Under the coordinated control of the drive module, each component realizes a fully automated closed loop of "inspection-decision-execution" for the package inspection, loading and unloading, and sorting process. Through the integrated execution of the core actions of "grabbing-transferring-fixed-point inspection-classification and placement" by the conveying fixture, the scattered manual visual inspection, manual handling, and sorting operations in the traditional process are integrated into a continuous, high-speed, and fully automated intelligent operation cycle. To a certain extent, it replaces the inefficient, error-prone, and costly manual operations, thereby improving the efficiency, accuracy, and reliability of inspection and sorting, and saving enterprises long-term labor costs.

[0008] Optionally, the conveying fixture includes a conveying seat. The horizontal drive module is used to drive the conveying seat to reciprocate above the input conveying platform, the detection platform, the waste collection platform, and the output conveying platform. The vertical drive module is used to drive the conveying seat to reciprocate in the vertical direction. Two opposing conveying clamps are slidably arranged on the conveying seat. A clamping plate drive member is provided on the conveying seat. The clamping plate drive member is used to drive the two conveying clamps to move in a direction that approaches or moves away from each other to clamp the package.

[0009] By adopting the above technical solution, the conveyor seat, as the core load-bearing and moving base, is driven by horizontal and vertical drive modules to move as a whole, realizing cross-regional horizontal transport and vertical lifting and positioning of packages between different workstations. When the conveyor seat carries two conveyor clamps to the target package and lowers into position, the clamp drive is activated, precisely driving the two opposing conveyor clamps to slide synchronously towards each other along the slide rail, so that they smoothly approach from both sides of the package and apply uniform clamping force, thereby firmly gripping packages of different sizes and shapes, effectively preventing them from shaking or slipping during high-speed transport. After clamping is completed, the conveyor seat rises and transfers the package to the inspection table for fixed-point inspection, or transfers it to the corresponding exit according to the inspection results. After reaching the target position, the clamp drive reverses its action, driving the two clamps to move away from each other, and smoothly releasing the package. By modularly integrating the clamping function onto an independently drivable conveyor, the two core actions of "movement" and "gripping" are decoupled and efficiently coordinated. This not only results in a compact structure but also precise and controllable clamping action, adapting to packages of different sizes. This avoids packages falling, being damaged, or having positioning deviations due to unstable gripping, ensuring a smooth, stable, and high-precision process from gripping, transferring, and pinpointing to sorting and delivery.

[0010] Optionally, a contact plate is rotatably disposed on each of the two conveying clamps on opposite sides. The contact plate is used to contact and clamp the package sidewall. One of the conveying clamps is provided with a first rotation drive unit, which is used to drive the contact plate disposed on the conveying clamp to rotate. The detection table includes a fixed base, on which a detection sleeve is rotatably disposed. The fixed base is provided with a second rotation drive unit for driving the detection sleeve to rotate. A receiving cavity is formed inside the detection sleeve for accommodating the conveying clamp, the contact plate, and the package. The visual inspection element is disposed on the inner wall of the detection sleeve.

[0011] By adopting the above technical solution, firstly, the conveyor clamp transfers and releases the package into the receiving cavity inside the detection sleeve, placing it stably on the fixed base. Then, the detection sleeve rotates under the drive of the second rotation drive unit. At this time, the visual inspection component fixedly installed on the inner wall of the detection sleeve can continuously or precisely scan the entire circumferential side of the package rotating with the detection sleeve, completing a 360-degree visual inspection of the package's sides. After completing the circumferential inspection, the conveyor clamp descends again, the two contact plates re-clamp the package, and the conveyor clamp moves the package upwards a certain distance. Subsequently, the first rotation drive unit is activated, driving one of the contact plates (and the side of the package it clamps) to rotate, while the opposite contact plate follows suit, causing the package to flip while clamped. This flipping action exposes the top and bottom surfaces of the package, as well as the bottom area previously blocked by contact with the fixed base, to the field of view of the visual inspection component, enabling supplementary imaging of the remaining surface of the package. Through this sequential inspection process of "first revolution (overall rotation to inspect the circumferential surface) then rotation (single-sided flip to inspect the top and bottom surfaces)," a relatively simple combination of mechanical motions is used to achieve efficient and complete visual inspection of all outer surfaces of the package without the need for complex multi-camera arrays or external flipping mechanisms, greatly improving the comprehensiveness and reliability of the inspection.

[0012] Optionally, a detection cavity is formed in the side wall of the detection sleeve. The detection cavity is optically connected to the receiving cavity through a transparent plate. The visual detection element is disposed in the detection cavity, and the transparent plate is used to close the detection cavity.

[0013] By adopting the above technical solution, after the package is sent into the receiving cavity of the detection sleeve, regardless of whether the detection sleeve itself rotates to scan the sides of the package or the contact plate drives the package to flip to expose the top and bottom surfaces, the visual inspection component set in the detection cavity acquires images of the package surface through a high-transmittance transparent plate. The transparent plate acts as a physical barrier, completely isolating the clean and controllable optical environment inside the detection cavity from dust, moisture, packaging debris, etc., that may be present in the receiving cavity. This effectively prevents contaminants from adhering to the lens or light source surface of the visual inspection component, ensuring the clarity and stability of the imaging. Simultaneously, the enclosed detection cavity structure also facilitates the construction of an independent and uniform illumination system, suppressing random interference from external ambient light and providing high-quality image input with constant lighting conditions for the AI ​​vision algorithm. Through the combined design of "cavity isolation" and "transparent observation window," the solution provides continuous and reliable physical protection and optical optimization for the core sensors of the vision system during dynamic and multi-pose detection processes, significantly improving the environmental adaptability, maintenance cycle, and accuracy of the final detection results of the entire device.

[0014] Optionally, a baffle plate extends from the conveyor seat to close the receiving cavity. The conveyor clamp includes a telescopic section and a fixed section. The clamp drive is used to drive the two telescopic sections to move in a direction that approaches or moves away from each other. The contact plate is rotatably disposed on the fixed section. The first rotation drive is disposed on the fixed section. The telescopic section is provided with a first telescopic drive for driving the fixed section to move vertically.

[0015] By adopting the above technical solution, the movement of the conveyor seat drives the baffle plate, fixed section, telescopic section, and contact plate to move together. When the conveyor seat moves to the position of the detection sleeve, the vertical drive module then drives the conveyor seat downwards until the package is stably placed on the fixed seat. The package is located in the receiving cavity, and the baffle plate then closes the receiving cavity. The baffle plate, detection sleeve, and fixed seat together form a closed space for package inspection, thereby improving the accuracy of the inspection process and avoiding interference from other external equipment. After the circumferential inspection of the package is completed, the contact plate re-clamps the package, and the telescopic section drives the fixed section to move upwards a certain distance. The contact plate and the clamped package then move upwards with the fixed section, disengaging the package from the fixed seat. This provides the necessary, interference-free suspended operating space for the package to be flipped while clamped. At this time, the first rotation drive unit can drive the contact plate and package to flip safely and smoothly, exposing the previously obscured top and bottom surfaces of the package to the field of view of the visual inspection component, completing the final full-surface inspection.

[0016] Optionally, the fixing base has a light groove, a light source is provided in the light groove, and a light-transmitting plate for closing the light groove is provided in the fixing base.

[0017] By adopting the above technical solution, when the conveying fixture carries the package into the receiving cavity of the inspection sleeve, the light source in the fixed seat light slot is turned on, and the light is diffused outward through the light-transmitting plate of the closed light slot, evenly illuminating the surface of the package in the receiving cavity. Then, the visual inspection component performs appearance defect inspection on the package illuminated by the light. After the inspection is completed, the light source is turned off, and the conveying fixture carries the package away from the inspection sleeve. By incorporating a light trough with a light-transmitting plate and a light source within the mounting base, active supplementary lighting for the detection area is achieved, solving the problem of decreased detection accuracy caused by insufficient or uneven ambient light in traditional visual inspection. The light-transmitting plate ensures effective light transmission from the light source while also protecting the light source within the light trough from dust and contamination, preventing package debris and dust from the food supply chain from entering the light trough and affecting the normal operation of the light source. Furthermore, the integrated supplementary lighting structure of the mounting base eliminates the need for an additional independent supplementary lighting device, simplifying the overall structural layout and reducing the space occupied by the equipment. The supplementary lighting is also closer to the detection area, highlighting minor stains, damage, and other defects on the package surface, further improving the recognition accuracy of visual inspection components and ensuring the reliability of food package appearance inspection.

[0018] Optionally, the fixed base has a placement groove, a cleaning brush is placed in the placement groove, a first telescopic rod is provided on the fixed base, one end of the cleaning brush is rotatably connected to the first telescopic rod, and an abutment plate is provided on the inner wall of the detection sleeve, the abutment plate is used to abut against the end of the cleaning brush away from the first telescopic rod.

[0019] By adopting the above technical solution, when the visual inspection component completes the inspection of a batch of packages, if the inner wall of the inspection sleeve becomes stained due to package friction and dust adhesion, affecting the subsequent inspection accuracy, the first telescopic rod on the fixed base extends. The extension of the first telescopic rod drives the cleaning brush to move out of the placement slot, and the bristles of the cleaning brush contact the fixed base. After that, the inspection sleeve is driven to rotate, and the rotation of the inspection sleeve drives the abutment plate to rotate. When the abutment plate rotates to abut against the end of the cleaning brush away from the first telescopic rod, the continued rotation of the inspection sleeve will push the cleaning brush to rotate around the connecting end of the first telescopic rod. At the same time, the cleaning brush and the fixed base rub against each other, thus cleaning the surface of the fixed base. After cleaning is completed, the extension and retraction of the first telescopic rod drives the cleaning brush to reset, and the inspection sleeve stops rotating. The automated cleaning of the inner wall of the detection sleeve is achieved through the cooperation of the first telescopic rod, the rotatable cleaning brush, and the detection sleeve abutment plate. This eliminates the need for manual disassembly and cleaning, effectively improving the equipment's continuous operation capability and avoiding excessive downtime and reduced operational efficiency caused by manual cleaning. The rotatable connection between the cleaning brush and the first telescopic rod, combined with the rotational movement of the detection sleeve, allows the cleaning brush to adhere to the inner wall of the detection sleeve, forming a comprehensive cleaning trajectory for a more thorough cleaning effect and preventing residual stains from affecting the imaging quality of subsequent visual inspection items. Furthermore, the cleaning structure is integrated into the fixed base and the detection sleeve, eliminating the need for additional independent cleaning equipment, simplifying the overall device structure, reducing manufacturing costs, and allowing the cleaning and inspection processes to alternate without interfering with the normal package inspection and sorting process, ensuring the continuity and stability of equipment operation.

[0020] Optionally, the waste collection platform is provided with a downwardly inclined sliding channel, in which a working position collection box and a standby position collection box are slidably disposed. The working position collection box is located below the moving trajectory of the conveying clamp, and the standby position collection box is located upstream of the working position collection box in the sliding direction. Two blocking members are correspondingly provided in the sliding channel to block and position the working position collection box and the standby position collection box respectively. A pushing member is also provided in the sliding channel to push the standby position collection box to the original position of the working position collection box to take over the waste collection.

[0021] By adopting the above technical solution, in the initial state, the working position collection box is located at the collection station below the moving trajectory of the conveyor fixture and is blocked and positioned by its corresponding blocking component, ready to receive non-conforming packages. Simultaneously, the standby collection box is located upstream in a spare position and is blocked and positioned by another blocking component. When the conveyor fixture continuously feeds non-conforming packages into the working position collection box until it reaches full load, the blocking component retracts, and the fully loaded working position collection box slides down the inclined channel away from the station under gravity. The kinetic energy of the sliding working position collection box, or the signal triggered after its release, will activate the pushing component, pushing the upstream standby collection box to overcome friction or minor resistance, accurately sliding it down to the original working position collection station, where it is blocked and positioned by the corresponding blocking component, thus taking over the role of the new "working position collection box" to continue receiving subsequent non-conforming products. At this time, the operator or the automatic feeder can add a new empty box upstream as a "standby collection box," completing one cycle. Through a relay-style coordination of "main container receiving - full container release - spare container pushing into place," this solution ensures that there are always containers available at the collection station, enabling continuous waste collection operations. In particular, the introduction of a mechanical "pushing component" provides active and reliable power for the placement of the spare container. Compared to relying entirely on gravity sliding, this ensures greater accuracy and reliability of the switching action, making it especially suitable for situations with insufficient channel inclination or high friction between the container and the channel. This significantly improves the robustness and automation level of the waste collection subsystem.

[0022] Optionally, the blocking member includes a blocking plate hinged within the sliding channel, and a torsion spring is sleeved on the hinge shaft of the blocking plate. One end of the torsion spring is connected to the sliding channel, and the other end is connected to the blocking plate.

[0023] By adopting the above technical solution, in the initial or empty state, the preload of the torsion spring drives the baffle plate to flip upwards, causing its end to protrude from the inner wall of the sliding channel, forming a mechanical stop, thereby reliably blocking the working or preparatory collection box that has slid to this position at the predetermined work station. When a defective package is put into the working collection box, increasing its total weight, the pressure of the box on the lower baffle plate gradually increases. Once the total weight of the working collection box and its internal packages exceeds the preset reset torque of the torsion spring, the box will press down on the baffle plate, causing it to overcome the torsion spring force and rotate downwards around the hinge axis until it is flush with or below the inner wall of the channel. At this point, the mechanical blockage is released, and the fully loaded working collection box slides away along the inclined channel under the action of gravity. After the collection box slides past, the baffle plate, which has lost its pressure, immediately and automatically springs back to its initial blocking position under the restoring force of the torsion spring, ready to intercept the next empty box. By combining the purely mechanical synergy of "torsion spring pretension to provide constant blocking force" and "gravity over-limit trigger automatic release", an adaptive and self-recovering intelligent blocking unit is created. It can automatically judge and execute blocking or releasing actions based on the real-time load status of the collection box (whether it is full or not), without the participation of sensors, controllers and actuators. This achieves fully automated management of the collection box at the work position, allowing it to "go when full and block when empty", which greatly simplifies system design and maintenance.

[0024] Optionally, the conveying fixture is provided with a stop plate, which can abut against the downward side of the working position collection box along the inclined direction of the sliding channel.

[0025] By adopting the above technical solution, when the conveying clamp, holding a defective package, moves above the workstation collection box positioned by the baffle, the conveying clamp first makes a slight adjustment, causing the baffle on it to descend and abut against the downward-facing side of the workstation collection box (i.e., the lower edge or wall of the box in the inclined channel), forming a temporary but stable mechanical limit. This abutment force acts directly on the box, and together with its own weight and the torsion spring force provided by the baffle, it forms a stable three-point force system, ensuring that the workstation collection box is completely locked before the package is placed. Subsequently, the clamp releases the package, and the package falls freely into the workstation collection box. Due to the presence of the baffle, even if the impact force of the falling package may momentarily increase the pressure of the workstation collection box on the baffle, even reaching the critical trigger threshold of the torsion spring, the downward trend of the workstation collection box is physically blocked because the lower edge of the workstation collection box is firmly held in place by the baffle. This avoids the risks of delivery failure and package splashing caused by the workstation collection box accidentally slipping or shifting during the package placement process. After delivery, the conveyor clamp, along with the baffle plate, rises and retracts, releasing the lock on the container. At this point, the fully loaded collection container relies entirely on the baffle plate for final load-bearing. Once its total weight meets the release conditions, it can be released and slid away normally. Through the sequential coordination of "dynamic contact locking" and "static elastic blocking," deterministic mechanical constraints are introduced in the most unstable stage of package delivery, effectively isolating the potential interference of dynamic impacts on the stability of the passive blocking mechanism.

[0026] In summary, this application includes at least one of the following beneficial technical effects: 1. Achieve a fully automated closed-loop inspection and sorting: By coordinating the input conveyor, inspection station, conveyor fixture and drive module, and integrating AI visual inspection technology, a fully automated "inspection-decision-execution" process is constructed to replace traditional manual operation, greatly improve inspection and sorting efficiency, avoid package backlog, and adapt to the needs of large-scale logistics operations. 2. Improve detection accuracy and food safety: Adopting a multi-view AI vision detection structure, combined with an active supplemental lighting system, it can achieve full-surface detection of the package without blind spots, reducing the rate of missed detections and false detections; at the same time, through the isolation and protection of the detection chamber and the automatic cleaning of the detection sleeve, it ensures the stability of the detection environment, further improving detection accuracy and reducing the safety risks caused by defects in food packages; 3. Reduce operating costs and maintenance difficulty: The automated structure reduces reliance on manual labor, saving on labor costs and training expenses; the integrated design of each functional module (such as the supplementary lighting structure integrated into the fixed base and the cleaning structure integrated into the testing table) simplifies the equipment layout and reduces manufacturing costs; the automated cleaning function extends the equipment maintenance cycle and reduces the amount of manual maintenance work. Attached Figure Description

[0027] Figure 1This is a schematic diagram of the overall structure of an AI vision-based intelligent loading, unloading, and sorting device in an embodiment of this application. Figure 2 This is a schematic diagram of the conveying fixture in the embodiments of this application; Figure 3 This is a cross-sectional view of the testing station in an embodiment of this application, where the delivery clamp holds the package inside the testing sleeve; Figure 4 This is a cross-sectional top view of the testing station in an embodiment of this application; Figure 5 This is a cross-sectional side view of the testing station in an embodiment of this application; Figure 6 This is a schematic diagram of the waste collection platform in an embodiment of this application.

[0028] Explanation of reference numerals in the attached drawings: 1. Input conveyor; 2. Inspection table; 201. Fixed base; 202. Inspection sleeve; 3. Waste collection table; 4. Output conveyor; 5. Fixture frame; 6. Vision inspection component; 7. Conveyor fixture; 701. Conveyor seat; 702. Conveyor clamp; 703. Clamp drive component; 7031. First motor; 7032. Bidirectional lead screw; 8. Horizontal drive module; 9. Vertical drive module; 901. Telescopic pneumatic rod; 10. Contact plate; 11. First rotation drive unit; 1101. Second motor; 12. Second rotation drive unit; 1201. Third motor; 1202. Drive gear; 1203. Gear ring; 13. Inspection chamber; 14. Transparent plate; 15. Baffle plate; 16. Telescopic section; 17. Fixed section; 18. First telescopic drive unit; 1801. Second telescopic rod; 19. Light trough; 20. Light source; 21. Light-transmitting plate; 22. Placement slot; 23. Cleaning brush; 24. Sealing gasket; 25. First telescopic rod; 26. Abutment plate; 27. Sliding channel; 28. Working position collection box; 29. ​​Preparatory position collection box; 30. Pushing component; 3001. Third telescopic rod; 3002. Pushing plate; 31. Baffle plate; 33. Abutment plate; 34. Receiving slot; 35. Sealing pad; 36. Sliding seat; 37. Slide groove; 38. Cleaning table; 39. Cleaning roller; 40. Wrap. Detailed Implementation

[0029] The following is in conjunction with the appendix Figure 1 -Appendix Figure 6 This application will be described in further detail.

[0030] This application discloses an intelligent loading, unloading, and sorting device based on AI vision. (Refer to...) Figures 1-6The AI ​​vision-based intelligent loading, unloading, and sorting device includes an input conveyor 1, an inspection station 2, a waste collection station 3, an output conveyor 4, and a fixture frame 5. The input conveyor 1 is used to dock and transport packages 40 to be sorted; the inspection station 2 is equipped with a vision inspection device 6 for inspecting packages 40; the waste collection station 3 is used to receive packages 40 that fail inspection; the output conveyor 4 is used to receive and transport packages 40 that pass inspection; the fixture frame 5 is movably equipped with a conveying fixture 7 for clamping and fixing packages 40. The fixture frame 5 is equipped with a horizontal drive module 8 and a vertical drive module 9. The horizontal drive module 8 is used to drive the conveying fixture 7 to reciprocate above the input conveyor 1, the inspection station 2, the waste collection station 3, and the output conveyor 4, and the vertical drive module 9 is used to drive the conveying fixture 7 to reciprocate in the vertical direction.

[0031] First, the package 40 to be sorted is automatically fed into the working range of the device via the input conveyor 1. Then, the horizontal and vertical drive modules 9 work in precision to drive the conveyor gripper 7 to grab the package 40 and accurately transfer it to the inspection table 2. After that, the vision inspection device 6 on the inspection table 2 performs image acquisition and AI analysis on the package 40 on the inspection table 2. After the inspection result is generated, the system controller immediately makes a decision: if the package 40 is unqualified, the drive module controls the conveyor gripper 7 to transfer and release it to the waste collection table 3 to achieve automatic rejection; if the package 40 is qualified, it is transferred to the output conveyor 4 to enter the next process.

[0032] Reference Figures 1-6 Both the input conveyor 1 and the output conveyor 4 are driven by conveyor belts and conveyor motors, and the conveying directions of the input conveyor 1 and the output conveyor 4 are opposite. The conveying fixture 7 includes a conveyor seat 701. A horizontal drive module 8 is used to drive the conveyor seat 701 to reciprocate above the input conveyor 1, the inspection table 2, the waste collection table 3, and the output conveyor 4. A vertical drive module 9 is used to drive the conveyor seat 701 to reciprocate in the vertical direction. Two opposing conveying clamps 702 are slidably arranged on the conveyor seat 701. A clamp drive component 703 is provided on the conveyor seat 701. The clamp drive component 703 is used to drive the two conveying clamps 702 to move in a direction that approaches or moves away from each other to clamp the package 40.

[0033] The conveyor seat 701 serves as the core support and moving base, driven by the horizontal and vertical drive modules 9 to move as a whole, enabling the horizontal transport and vertical lifting and positioning of the package 40 across different workstations. When the conveyor seat 701, carrying two conveyor clamps 702, moves above the target package 40 and descends into position, the clamp drive component 703 is activated, precisely driving the two opposing conveyor clamps 702 to slide synchronously towards each other along the slide rail, allowing them to smoothly approach from both sides of the package 40 and apply uniform clamping force, thereby firmly gripping packages 40 of different sizes and shapes, effectively preventing them from shaking or slipping during high-speed transport. After clamping, the conveyor seat 701 rises and transfers the package 40 to the inspection table 2 for fixed-point inspection, or transfers it to the corresponding exit according to the inspection results. Upon reaching the target position, the clamp drive component 703 reverses its action, driving the two clamps to move away from each other, smoothly releasing the package 40.

[0034] Reference Figures 1-6 Two conveying clamps 702 are each rotatably provided with a contact plate 10 on one side opposite to the other. The contact plate 10 is used to contact and clamp the package 40. One of the conveying clamps 702 is provided with a first rotation drive part 11, which is used to drive the contact plate 10 on the conveying clamp 702 to rotate. The detection table 2 includes a fixed base 201, on which a detection sleeve 202 is rotatably provided. The fixed base 201 is provided with a second rotation drive part 12 for driving the detection sleeve 202 to rotate. The detection sleeve 202 forms a receiving cavity for accommodating the conveying clamp 702, the contact plate 10 and the package 40. The visual inspection element 6 is provided on the inner wall of the detection sleeve 202.

[0035] Reference Figures 1-6The horizontal drive module 8 includes a slide rail (not shown in the figure) mounted on the fixture frame 5. The slide rail is arranged along the direction of the input conveyor 1, the inspection table 2, the output conveyor 4, and the waste collection table 3. A sliding seat 36 is slidably mounted on the slide rail. A power source for driving the sliding seat 36 to slide on the slide rail is provided on the fixture frame 5 (the cooperation between the sliding seat 36 and the slide rail can refer to the configuration in the prior art). The vertical drive module 9 includes a telescopic air rod 901 mounted on the sliding seat 36. The telescopic air rod 901 is arranged vertically, and the fixed end of the telescopic air rod 901 is connected to the slide rail. The movable seat 36 is fixedly connected, and the movable end of the telescopic air rod 901 is fixedly connected to the conveyor seat 701. A horizontal groove 37 is provided on the conveyor seat 701. The top end of the conveyor clamp 702 is located within the groove 37 and slidably connected to it. The clamp drive 703 includes a bidirectional lead screw 7032 rotatably disposed within the groove 37. A first motor 7031 is provided on the conveyor seat 701. The output shaft of the first motor 7031 is coaxially and fixedly connected to the bidirectional lead screw 7032. The bidirectional lead screw 7032 is horizontally positioned, and the two conveyor clamps 702 are respectively connected to… The bidirectional lead screw 7032 is fixedly connected to two lead screw nuts. The rotation of the output shaft of the first motor 7031 drives the bidirectional lead screw 7032 to rotate. Since the threads of the two parts of the bidirectional lead screw 7032 rotate in opposite directions, the two conveyor clamps 702 can move towards or away from each other. The first rotation drive unit 11 includes a second motor 1101 mounted on one of the conveyor clamps 702. The output shaft of the second motor 1101 is coaxially and fixedly connected to the rotating shaft of the contact plate 10 mounted on the conveyor clamp 702. The second rotation... The drive unit 12 includes a third motor 1201 disposed on one side of the fixed base 201. The output shaft of the third motor 1201 is vertically arranged. A drive gear 1202 is coaxially fixedly connected to the output shaft of the third motor 1201. A gear ring 1203 is fixed to the inner peripheral wall of the bottom of the detection sleeve 202. The drive gear 1202 and the gear ring 1203 mesh with each other. The rotation of the output shaft of the third motor 1201 can drive the drive gear 1202 to rotate, and the drive gear 1202 in turn drives the gear ring 1203 to rotate, thereby rotating the detection sleeve 202.

[0036] Reference Figures 1-6 A baffle plate 15 extends from the conveyor seat 701 to close the receiving cavity. The conveyor clamp 702 includes a telescopic section 16 and a fixed section 17. The two telescopic sections 16 are respectively fixedly connected to the two screw nuts of the bidirectional screw 7032. The second motor 1101 and the contact plate 10 are both disposed on the fixed section 17. The telescopic section 16 is provided with a first telescopic drive part 18 for driving the fixed section 17 to move vertically.

[0037] The movement of the conveyor seat 701 causes the baffle plate 15, the fixed section 17, the telescopic section 16, and the contact plate 10 to move together. When the conveyor seat 701 moves to the position of the detection sleeve 202, the vertical drive module 9 then drives the conveyor seat 701 to move down until the package 40 is stably placed on the fixed seat 201. The package 40 is located in the receiving cavity. At this time, the baffle plate 15 closes the receiving cavity. The baffle plate 15, the detection sleeve 202, and the fixed seat 201 together form a closed space for detecting the package 40, thereby improving the accuracy of the detection process and avoiding interference from the presence of other external equipment. After the peripheral inspection of package 40 is completed, the contact plate 10 clamps package 40 again. The telescopic section 16 drives the fixing section 17 to move upward a certain distance. The contact plate 10 and the clamped package 40 move upward with the fixing section 17, and package 40 disengages from the fixing seat 201. Subsequently, the first rotation drive unit 11 is activated, driving one of the contact plates 10 (and one side of the package 40 it clamps) to rotate. The opposite contact plate 10 moves in coordination, causing package 40 to flip in the clamped state. This flipping action exposes the top surface, bottom surface, and bottom area of ​​package 40 that were previously blocked by contact with the fixing seat 201 to the field of view of the visual inspection element 6, enabling supplementary imaging of the remaining surface of package 40.

[0038] Reference Figures 1-6 The first telescopic drive unit 18 includes a vertically arranged electrically controlled second telescopic rod 1801. The fixed end of the second telescopic rod 1801 is fixedly connected to the telescopic section 16, and the movable end of the second telescopic rod 1801 is fixedly connected to the fixed section 17. The fixed section 17 can be driven to move vertically by the telescopic movement of the second telescopic rod 1801.

[0039] Reference Figures 1-6The detection sleeve 202 has a detection cavity 13 in the side wall. The detection cavity 13 is optically connected to the receiving cavity through a transparent plate 14. The visual inspection element 6 is set in the detection cavity 13. The transparent plate 14 is used to close the detection cavity 13. After the package 40 is sent into the receiving cavity in the detection sleeve 202, whether the detection sleeve 202 rotates itself to scan the side of the package 40 or the contact plate 10 drives the package 40 to flip to expose the top and bottom surfaces, the visual inspection element 6 set in the detection cavity 13 will collect images of the surface of the package 40 through the transparent plate 14 with high light transmittance. A light slot 19 is provided in the fixed base 201, and a light source 20 is provided in the light slot 19. A light-transmitting plate 21 for sealing the light slot 19 is provided in the fixed base 201. When the conveying clamp 7 carries the package 40 into the receiving cavity of the inspection sleeve 202, the light source 20 in the light slot 19 of the fixed base 201 is turned on. The light is diffused outward through the light-transmitting plate 21 that seals the light slot 19, and evenly illuminates the surface of the package 40 in the receiving cavity. Then the visual inspection component 6 performs appearance defect inspection on the package 40 illuminated by the light. After the inspection is completed, the light source 20 is turned off, and the conveying clamp 7 carries the package 40 away from the inspection sleeve 202.

[0040] Reference Figures 1-6 The fixed base 201 has a placement groove 22. Two opposing sealing pads 35 are provided at the opening of the placement groove 22. The ends of the two sealing pads 35 are fitted together to seal the placement groove 22. A cleaning brush 23 is provided inside the placement groove 22. The fixed base 201 has a receiving groove 34. An electrically controlled first telescopic rod 25 is provided inside the receiving groove 34. The first telescopic rod 25 is vertically arranged and can be completely contained in the receiving groove 34. One end of the cleaning brush 23 is rotatably connected to the first telescopic rod 25. An abutment plate 26 is provided on the inner wall of the detection sleeve 202. The abutment plate 26 is used to abut against the end of the cleaning brush 23 away from the first telescopic rod 25.

[0041] After the visual inspection component 6 completes the inspection of a batch of packages 40, if the inner wall of the inspection sleeve 202 becomes stained due to friction and dust adhesion of the packages 40, affecting the accuracy of subsequent inspections, the first telescopic rod 25 on the fixed base 201 extends. The extension of the first telescopic rod 25 drives the cleaning brush 23 to move out of the placement slot 22, and the bristles of the cleaning brush 23 come into contact with the fixed base 201. After this, the inspection sleeve 202 is driven to rotate, and the rotation of the inspection sleeve 202 drives the abutment plate 26 to rotate. When the abutment plate 26 rotates to abut against the end of the cleaning brush 23 away from the first telescopic rod 25, the continued rotation of the inspection sleeve 202 will push the cleaning brush 23 to rotate around the connecting end of the first telescopic rod 25. At the same time, the cleaning brush 23 rubs against the fixed base 201, thus cleaning the surface of the fixed base 201. After cleaning is completed, the extension and retraction of the first telescopic rod 25 drives the cleaning brush 23 to reset, and the inspection sleeve 202 stops rotating.

[0042] Reference Figures 1-6The waste collection platform 3 has a downward-sloping sliding channel 27. A working position collection box 28 and a standby position collection box 29 are slidably arranged in the sliding channel 27. The working position collection box 28 is located below the moving trajectory of the conveying clamp 7, and the standby position collection box 29 is located upstream of the working position collection box 28 in the sliding direction. Two blocking members are correspondingly arranged in the sliding channel 27 to block and position the working position collection box 28 and the standby position collection box 29, respectively. A pushing member 30 is also arranged in the sliding channel 27 to push the standby position collection box 29 to the original position of the working position collection box 28 to take over the waste collection.

[0043] Reference Figures 1-6 The pushing component 30 includes an electrically controlled third telescopic rod 3001 disposed in the sliding channel 27. The third telescopic rod 3001 is disposed along the inclined direction of the sliding channel 27. A pushing plate 3002 is fixed to the movable end of the third telescopic rod 3001. The pushing plate 3002 is driven to move by the telescopic movement of the movable end of the third telescopic rod 3001, thereby pushing the preparatory collection box 29.

[0044] Initially, the working station collection box 28 is located at the collection station below the moving trajectory of the conveyor clamp 7 and is positioned by its corresponding blocking component, ready to receive defective packages 40. Simultaneously, the standby collection box 29 is located upstream in a spare position and is positioned by another blocking component. As the conveyor clamp 7 continuously feeds defective packages 40 into the working station collection box 28 until it reaches full load, the blocking component retracts, and the fully loaded working station collection box 28 slides down the inclined channel under gravity, leaving the station. The kinetic energy of the working station collection box 28's descent, or the signal triggered by its release, activates the pusher 30, pushing the upstream standby collection box 29 to overcome friction or minor resistance and precisely slide down to the original working station collection box 28's collection station, where it is positioned by the corresponding blocking component, thus taking over the role of the new "working station collection box 28" and continuing to receive subsequent defective products.

[0045] Reference Figures 1-6 The blocking component includes a blocking plate 31 hinged in the sliding channel 27. A torsion spring (not shown in the figure) is sleeved on the hinge shaft of the blocking plate 31. One end of the torsion spring is connected to the sliding channel 27, and the other end is connected to the blocking plate 31. A stop plate 33 is provided on the conveying seat 701. Along the inclined direction of the sliding channel 27, the stop plate 33 can abut against the downward side of the working position collection box 28.

[0046] When the conveying clamp 7, holding the defective package 40, moves above the workstation collection box 28 positioned by the baffle plate 31, the conveying clamp 7 first makes a slight adjustment, causing the baffle plate 33 on it to descend and abut against the downward-facing side of the workstation collection box 28 (i.e., the lower edge or wall of the box in the inclined channel), forming a temporary but stable mechanical limit. This abutment force acts directly on the box, and together with its own weight and the torsion spring force provided by the baffle plate 31, it forms a stable three-point force system, ensuring that the workstation collection box 28 is completely locked before the package 40 is placed. Subsequently, the clamp releases the package 40, and the package 40 falls freely into the workstation collection box 28. When the total weight of the workstation collection box 28 and the package 40 inside exceeds the preset reset torque of the torsion spring, the box will press down the baffle plate 31, causing it to overcome the torsion spring force and rotate downward around the hinge axis until it is flush with or below the inner wall of the channel. At this point, the mechanical blockage is released, and the fully loaded workstation collection box 28 then slides away along the inclined channel under the action of gravity.

[0047] Reference Figures 1-6 A cleaning platform 38 is also provided on one side of the waste collection platform 3. A cleaning roller 39 is provided on the cleaning platform 38. The conveying clamp 702 can drive the contact plate 10 to move to contact the cleaning roller 39 to complete the cleaning of the contact plate 10.

[0048] The visual inspection component 6 includes an industrial camera module, an AI image processing module, and a data transmission unit. The industrial camera module consists of multiple sets of high-definition industrial area array cameras and matching telecentric lenses, evenly distributed circumferentially along the inner wall of the inspection sleeve 202, forming a 360° all-around shooting layout. The camera's shooting frame rate is no less than 30fps, and the resolution is no less than 1920×1080. It supports automatic exposure and white balance adjustment, adapting to imaging the surface of packages 40 made of different packaging materials (plastic, paper, and film). The AI ​​image processing module is integrated inside the camera, containing a pre-trained defect recognition model for food packages 40. The model has been trained and optimized using numerous defect samples such as stains, damage, and poor sealing, and possesses defect feature extraction, classification, and confidence level determination functions. The package 40 images captured by the industrial camera module are transmitted to this module in real time. After image preprocessing (noise reduction, enhancement, distortion correction), defect recognition, and feature matching, the module outputs "qualified / unqualified" inspection results and defect type data. The data transmission unit uses an industrial Ethernet interface or a wireless communication module to synchronously transmit the detection results of the AI ​​image processing module to the main controller of the device. The main controller then controls the horizontal and vertical drive modules 9 to perform sorting actions.

[0049] This device also includes a main controller (model optional: PLC S7-1200), which is fixedly installed on one side of the fixture frame 5. It is electrically connected via wires to the power source of the horizontal drive module 8, the telescopic pneumatic rod 901 of the vertical drive module 9, the first motor 7031, the second motor 1101, the third motor 1201, the first telescopic rod 25, the second telescopic rod 1801, the third telescopic rod 3001, the light source 20, and the vision inspection component 6, achieving coordinated control of all components. The power supply system uses industrial 220V AC power, which is converted to 24V DC by a transformer to power the various electrical control components. An emergency backup power supply is also provided to ensure data preservation and safe shutdown in the event of a sudden power outage. The specific control logic is as follows: 1. The conveyor motor of the input conveyor 1 starts, conveying package 40 to the preset gripping position, triggering the position sensor (model optional E3F-DS30C4) to send a signal to the main controller; 2. The main controller controls the horizontal drive module 8 to drive the sliding seat 36 to move above the gripping position, and then controls the telescopic air rod 901 of the vertical drive module 9 to extend, driving the conveyor seat 701 to descend; 3. The main controller controls the first motor 7031 to start, driving the bidirectional lead screw 7032 to rotate, so that the two conveyor clamps 702 approach and clamp package 40; 4. After clamping, the telescopic air rod 901 retracts, the horizontal drive module 8 drives the conveyor seat 701 to move above the detection table 2, the telescopic air rod 901 extends again, and puts package 40 into the receiving cavity of the detection sleeve 202; 5. The main controller controls the light source 20 to start, and simultaneously controls the third motor 1201 to start, driving the detection sleeve 202 to rotate. The vision detection component 6 begins to collect images of the package 40 and transmits them to the AI ​​image processing module. The processed detection results are sent to the main controller through the data transmission unit; 6. If the detection result is qualified, the main controller controls the conveying clamp 7 to clamp the package 40, and moves the package 40 to the top of the output conveyor 4 and releases it through the horizontal and vertical drive modules 9; if the detection result is unqualified, it is moved to the top of the waste collection platform 3, and the baffle 33 is controlled to abut against the working position collection box 28 and release the package 40; 7. When the working position collection box 28 is fully loaded and presses down the baffle 31 to slide down, the photoelectric sensor (model optional E3Z-LS63) in the channel triggers a signal, and the main controller controls the third telescopic rod 3001 to extend, pushing the preparatory position collection box 29 to the working position and being positioned by the baffle 31; 8. After each batch of 10 packages 40 is inspected, the main controller controls the first telescopic rod 25 to extend, driving the cleaning brush 23 to clean the inner wall of the inspection sleeve 202, and then resets it after cleaning; at the same time, the main controller controls the conveying clamp 7 to move the contact plate 10 to the cleaning roller 39, and the contact plate 10 and the cleaning roller 39 make contact in a moving manner to realize the automated cleaning of the contact plate 10.

[0050] The implementation principle of an AI vision-based intelligent loading, unloading, and sorting device in this application embodiment is as follows: An integrated device is constructed, consisting of an input conveyor 1, an inspection station 2, an inspection station with a vision inspection component 6, a waste collection station 3, an output conveyor 4, and a multi-dimensional movable conveying fixture 7. Under the coordinated control of the drive module, each component realizes a fully automated closed loop of "inspection-decision-execution" for the inspection, loading, unloading, and sorting process of packages 40. The core actions of "grabbing-transferring-fixed-point inspection-classification and placement" are performed in an integrated manner through the conveying fixture 7. The scattered manual visual inspection, manual handling, and sorting operations in the traditional process are integrated into a continuous, high-speed, and fully automated intelligent operation cycle, which to a certain extent replaces the inefficient, error-prone, and costly manual operation, thereby improving the efficiency, accuracy, and reliability of inspection and sorting, and saving enterprises long-term labor costs.

[0051] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An intelligent loading, unloading, and sorting device based on AI vision, characterized in that: include: An input conveyor (1) is used to dock with and transport packages (40) to be sorted; Inspection station (2), on which a visual inspection device (6) is provided for inspecting the package (40); Waste collection station (3) for receiving the package (40) that fails the inspection; Output conveyor (4) is used to receive and convey qualified packages (40) after inspection; A clamp frame (5) is provided with a conveying clamp (7) for clamping and fixing the package (40). A horizontal drive module (8) and a vertical drive module (9) are provided on the clamp frame (5). The horizontal drive module (8) is used to drive the conveying clamp (7) to reciprocate above the input conveying table (1), the detection table (2), the waste collection table (3), and the output conveying table (4). The vertical drive module (9) is used to drive the conveying clamp (7) to reciprocate in the vertical direction.

2. The intelligent loading, unloading, and sorting device based on AI vision according to claim 1, characterized in that: The conveying fixture (7) includes a conveying seat (701). The horizontal drive module (8) is used to drive the conveying seat (701) to reciprocate above the input conveying platform (1), the detection platform (2), the waste collection platform (3), and the output conveying platform (4). The vertical drive module (9) is used to drive the conveying seat (701) to reciprocate in the vertical direction. Two opposing conveying clamps (702) are slidably arranged on the conveying seat (701). A clamping plate drive member (703) is provided on the conveying seat (701). The clamping plate drive member (703) is used to drive the two conveying clamps (702) to move in a direction that approaches or moves away from each other to clamp the package (40).

3. The intelligent loading, unloading, and sorting device based on AI vision according to claim 2, characterized in that: A contact plate (10) is rotatably provided on one side of each of the two conveying clamps (702). The contact plate (10) is used to contact and clamp the package (40) with the side wall of the package (40). A first rotation drive part (11) is provided on one of the conveying clamps (702). The first rotation drive part (11) is used to drive the contact plate (10) provided on the conveying clamp (702) to rotate. The detection table (2) includes a fixed base (201). A detection sleeve (202) is rotatably provided on the fixed base (201). A second rotation drive part (12) is provided on the fixed base (201) to drive the detection sleeve (202) to rotate. A receiving cavity is formed inside the detection sleeve (202) to accommodate the conveying clamp (702), the contact plate (10) and the package (40). The visual inspection element (6) is provided on the inner wall of the detection sleeve (202).

4. The intelligent loading, unloading, and sorting device based on AI vision according to claim 3, characterized in that: The detection sleeve (202) has a detection cavity (13) in the side wall. The detection cavity (13) is optically connected to the receiving cavity through a transparent plate (14). The visual detection element (6) is disposed in the detection cavity (13). The transparent plate (14) is used to close the detection cavity (13).

5. The intelligent loading, unloading, and sorting device based on AI vision according to claim 3, characterized in that: A baffle plate (15) extends from the conveyor seat (701) and is used to close the receiving cavity. The conveyor clamp (702) includes a telescopic section (16) and a fixed section (17). The clamp drive (703) is used to drive the two telescopic sections (16) to move in a direction that approaches or moves away from each other. The contact plate (10) is rotatably disposed on the fixed section (17). The first rotation drive part (11) is disposed on the fixed section (17). The telescopic section (16) is provided with a first telescopic drive part (18) for driving the fixed section (17) to move vertically.

6. The intelligent loading, unloading, and sorting device based on AI vision according to claim 5, characterized in that: The fixing base (201) has a light groove (19) inside, a light source (20) is provided in the light groove (19), and a light-transmitting plate (21) for closing the light groove (19) is provided in the fixing base (201).

7. The intelligent loading, unloading, and sorting device based on AI vision according to claim 3, characterized in that: The fixed base (201) is provided with a placement groove (22), and a cleaning brush (23) is provided in the placement groove (22). The fixed base (201) is provided with a first telescopic rod (25). One end of the cleaning brush (23) is rotatably connected to the first telescopic rod (25). The inner wall of the detection sleeve (202) is provided with an abutment plate (26), which is used to abut against the end of the cleaning brush (23) away from the first telescopic rod (25).

8. The intelligent loading, unloading, and sorting device based on AI vision according to claim 1, characterized in that: The waste collection platform (3) is provided with a downwardly inclined sliding channel (27). A working position collection box (28) and a standby position collection box (29) are slidably arranged in the sliding channel (27). The working position collection box (28) is located below the moving trajectory of the conveying clamp (7), and the standby position collection box (29) is located upstream of the working position collection box (28) in the sliding direction. Two blocking members are provided in the sliding channel (27) to block and position the working position collection box (28) and the standby position collection box (29) respectively. A pushing member (30) is also provided in the sliding channel (27). The pushing member (30) is used to push the standby position collection box (29) to the original position of the working position collection box (28) to take over the waste collection.

9. The intelligent loading, unloading, and sorting device based on AI vision according to claim 8, characterized in that: The blocking component includes a blocking plate (31) hinged in the sliding channel (27). A torsion spring is sleeved on the hinge shaft of the blocking plate (31). One end of the torsion spring is connected to the sliding channel (27), and the other end is connected to the blocking plate (31).

10. The intelligent loading, unloading, and sorting device based on AI vision according to claim 9, characterized in that: The conveying clamp (7) is provided with a baffle plate (33), which can abut against the downward side of the working position collection box (28) along the inclined direction of the sliding channel (27).

Images