Automatic batching system for transverse shear column materials and batching method of automatic batching system

Abstract

The invention relates to the technical field of automatic batching, and provides an automatic batching system and method for columnar materials, and the system comprises a material generation module, an automatic transfer module, a cache storage module and a central control module. The material generation module is used for processing raw materials into columnar material units; the automatic transfer module is provided with a guide path, a moving unit and a carrying execution assembly and used for achieving automatic carrying of the material units. The cache storage module comprises a plurality of material storage positions, and each position is provided with a state detection assembly used for monitoring the storage state in real time. The central control module is responsible for coordinated operation of the whole system and comprises a communication sub-module, an identification management sub-module, a storage mapping sub-module, a matching decision sub-module, an instruction generation sub-module, a data updating sub-module and the like. The system constructs an information closed loop of the whole process of material batching, supports dynamic scheduling and abnormal recovery, has the advantages of being accurate in operation, high in efficiency, high in traceability and the like, and is suitable for automatic batching operation in various industrial production environments.

Description

Technical Field

[0001] This invention relates to the fields of intelligent manufacturing and automated logistics technology, and in particular to an automatic batching system and method for cross-cutting column materials. Background Technology

[0002] In the manufacturing processes of iron cores for motors, transformers, and other equipment, silicon steel sheets are processed by cross-cutting lines to form sheets of different sizes. These sheets are then stacked into cylindrical blocks of specified height and weight (referred to as "pillars") for subsequent processes. The types, sizes, and batches of these pillars are numerous and highly dependent on subsequent processing steps. Therefore, the automated sorting, accurate matching, and standardized storage of these pillars are crucial for ensuring production efficiency and product quality.

[0003] However, the industry currently still predominantly uses manual material handling, which has many problems. These problems are closely related and form a major bottleneck restricting intelligent manufacturing.

[0004] The material feeding process is highly dependent on manual labor, resulting in efficiency bottlenecks and operational instability. In the existing model, operators need to visually identify the length, weight, and label information of the material column, and combine this with experience to determine its appropriate buffer location. This decision-making and operational process is not only slow and demanding, but also prone to misjudgment or misplacement. On the one hand, it increases the workload, and on the other hand, it becomes a bottleneck in the cycle time of the entire cross-cutting production line, limiting the automation level of the production line.

[0005] Manual matching is prone to errors, leading to mismatches between stock items and cache storage locations, impacting subsequent processes. Because stock items come in various specifications, and each type often has specific subsequent usage requirements (e.g., different stacking machines or different orders), manual operation is prone to placing stock items in the wrong storage locations due to memory errors or view confusion. Such mismatches may not be immediately apparent, but they can cause process mismatches, material waste, and even lead to the scrapping of the entire batch of products, resulting in a batch quality incident.

[0006] Meanwhile, the lag or inconsistency in cache location status information causes logistics chaos. Existing cache location management methods mostly rely on static means such as manual records or labels, which cannot reflect key information such as the real-time occupancy of the location and the specifications of the stored materials. Once operators change shifts or make mistakes, the location status can easily become inconsistent with the records, leading to problems such as unused empty locations, misfilling of full locations, and duplicate material feeding, which seriously affects cache efficiency and material flow.

[0007] The disconnect between the material handling process and the MES system, coupled with a lack of data closure, hinders lean management. Currently, the material handling process is often not integrated with the upper-level MES system, making it impossible to automatically upload and track information such as the generation time, destination, and intended use of each material. This information silo phenomenon makes production data difficult to trace, and management struggles to use real-time data for capacity analysis, bottleneck identification, and process optimization, further weakening the digitalization level of the workshop.

[0008] In summary, existing column material cutting processes are not only inefficient and prone to mismatches, but also suffer from chaotic management and data fragmentation. The root cause lies in the lack of a systematic approach capable of simultaneously achieving column material identification, information binding, dynamic matching, and real-time data feedback. Even though some factories have begun using robotic arms or sensors to improve the automation level of single-point actions, the fundamental problem of intelligent material cutting remains unsolved due to the failure to achieve the integration of "information flow, material flow, and control flow." Summary of the Invention

[0009] In this section, as well as in the abstract and title of this application, some simplifications or omissions may be made to avoid obscuring the purpose of this section, the abstract, and the title of this application, and such simplifications or omissions shall not be used to limit the scope of the invention.

[0010] To address the shortcomings of existing technologies, one objective of this invention is to provide an automatic batching system for columnar materials, comprising: a material generation module for processing raw materials to form columnar material units; an automatic transfer module including a guide path disposed between the material generation module and a buffer area, a moving unit running along the guide path, and a handling execution component mounted on the moving unit, the handling execution component being used to grasp, move, and deliver the columnar material units; and a buffer storage module having multiple material storage locations, each material storage location being equipped with a status detection component for collecting the occupancy status and material information of that location. A central control module is used to coordinate the operation of the material generation module, the automatic transfer module, and the cache storage module. The central control module includes: The communication submodule is used to collect production information of the columnar material unit; The management submodule is used to generate and bind unique identifiers to each columnar material unit; The storage mapping submodule is used to establish and update the virtual mapping structure of the cache storage module; The matching decision submodule is used to select a matching storage target from multiple free locations based on at least one preset rule; The instruction generation submodule is used to generate path and motion control instructions for driving the automatic transfer module to perform handling operations; the data update submodule is used to update the virtual storage structure state and record the batching operation data after the material is handled. The automatic transfer module, the cache storage module, and the central control module form a collaborative closed loop to achieve fully automated processing of the columnar material unit's processing, handling, caching, and information management.

[0011] In one possible implementation, the status detection component includes at least one of the following sensing devices: a photoelectric sensor, a visual recognition unit, a pressure detection module, and a laser ranging module. The installation location is the top, side wall, or bottom of the material storage location. The component is used to detect from multiple dimensions whether the storage location is vacant, occupied, or in an abnormal state, and to feed back the detection results to the central control module in real time.

[0012] In one possible implementation, the handling execution component includes a multi-degree-of-freedom robotic arm disposed on the mobile unit, the robotic arm including: a lifting mechanism for vertical height adjustment; A rotating clamping structure is provided at the end of the lifting mechanism to realize the clamping and rotational adjustment of the columnar material unit; A positioning correction mechanism is located at the end of the clamping structure and is used to correct the lateral or orientation deviation of the columnar material unit in real time during the placement process.

[0013] In one possible implementation, the matching decision submodule employs a multi-level, configurable priority matching strategy and supports dynamic weight adjustment. The strategy includes: priority rules based on location distance; and classification rules based on the concentration of material specifications. Load balancing rules based on cache levels; Gravity stratification rules based on material weight; Targeted reservation rules based on order tags; Each rule can be enabled individually or executed in combination, and online switching and policy updates are supported to adapt to various production scenarios.

[0014] In one possible implementation, the virtual storage structure constructed by the storage mapping submodule is a node-based dynamic database. Each node includes the following fields: location number, three-dimensional coordinates, current status label, bound material identifier, material specification parameters, batch number, availability level, and update timestamp. The database is periodically compared with the data of the status detection component to ensure information synchronization.

[0015] In one possible implementation, the transport instructions issued by the instruction generation submodule include the following control parameters: Three-dimensional coordinates of the target location; Path trajectory node sequence; Clamping method and force parameters; The range of vertical movement; Rotation angle setting; Fault tolerance retry threshold; The instructions are sent to the motion controller of the mobile unit via an industrial-grade communication protocol and have task interruption and recovery functions.

[0016] In one possible implementation, an automatic batching control method based on an automatic batching system for columnar materials is provided, comprising the following steps: S1. The central control module receives material generation signals and material parameter information from the material generation module through the communication submodule, and the identification management submodule assigns a unique identifier to each columnar material unit and establishes a material information binding relationship. S2. The status detection component collects the status of each material storage location in the cache storage module, and the storage mapping submodule constructs or updates the virtual storage structure in real time based on the collection results to synchronously reflect the physical cache status. S3. The matching decision submodule performs target storage location matching logic based on the current virtual storage structure state and preset priority strategy, and selects a target location that is compatible with the current columnar material unit; S4. The instruction generation submodule generates a transport control instruction, including path, clamping action, pose control and abnormal strategy, based on the target position coordinates and the motion characteristics of the automatic transfer module, and sends it to the mobile unit for execution. S5. The handling execution component completes the handling and placement operation of the columnar material unit according to the received control command, and the status detection component confirms the material's arrival status; S6. After placement confirmation, the data update submodule updates the status information of the corresponding node in the virtual storage structure, binds the material identifier to the target location, and records a complete batching execution log to achieve traceability and closed-loop data management of the batching process.

[0017] In one possible implementation, the matching process in step S4 is a progressive screening process. The matching decision submodule first performs an initial screening according to the highest priority rule. When there are multiple target positions that meet the conditions, the next level of priority rule is introduced to refine the screening until a unique target position is matched. If no match is found after all rules have been executed, the default allocation strategy is executed to complete the instruction generation.

[0018] In one possible implementation, in step S6, after the state detection component confirms that the columnar material unit has been successfully placed in the target storage location and outputs a location confirmation signal, the data update submodule performs the following operation: establishes a one-to-one binding relationship between the unique identifier of the columnar material unit and the location information of the target storage location, and writes the binding relationship into the storage database; Synchronously update the occupancy status, binding identifier, and availability attributes of the corresponding nodes in the virtual storage structure; generate and archive the ingredient record information corresponding to this ingredient dispensing operation; The batching record information includes at least one or more of the following fields: unique identifier of columnar material unit, target storage location number, batching completion time, handling execution result status, anomaly marker information, and execution instruction identifier, which are used to support subsequent production traceability, scheduling analysis, and anomaly review.

[0019] In one possible implementation, during the transfer process in step S5, if the virtual storage structure reports a change in the status of the current target storage location and it no longer meets the availability conditions, the following dynamic rescheduling process is executed: a. The central control module immediately triggers the material handling task interruption process, suspends the current material handling action of the automatic transfer module, and records the interruption event identifier and triggering reason; b. The storage mapping submodule refreshes the status information of all storage locations and reconstructs the virtual storage structure in real time to reflect the latest physical cache status; c. The matching decision submodule re-executes the target location matching logic based on the updated virtual storage structure to obtain new available target locations; d. The instruction generation submodule regenerates the handling control instruction based on the new target position parameters and sends it to the automatic transfer module in real time via the communication link; e. The transport execution component continues to complete the transport and placement operation of the columnar material unit according to the updated transport instructions; the data update submodule completes placement confirmation, status update, identifier binding and abnormal process recording, which is used for autonomous response control and abnormal recovery closed-loop management during the transport process.

[0020] The beneficial effects of the automatic batching system for columnar materials of the present invention are as follows: By setting up a material generation module, an automatic transfer module, a buffer storage module, and a central control module to cooperate with each other, the present invention can realize the full-process automation of columnar material units from generation and transportation to buffering. This solves the problems of reliance on manual handling, chaotic material management, and difficulty in information traceability in the traditional batching process, making the batching process more intelligent and efficient, and facilitating enterprises to achieve refined management and full-process tracking of production processes.

[0021] To address the shortcomings of existing technologies, another objective of this invention is to provide an automatic batching control method based on an automatic batching system for columnar materials.

[0022] To achieve the above objectives, the present invention adopts the following technical solution: an automatic batching control method based on an automatic batching system for columnar materials, wherein the automatic batching system for columnar materials is used and operated according to the following steps: S1. The central control module receives material generation signals and material parameter information from the material generation module through the communication submodule, and the identification management submodule assigns a unique identifier to each columnar material unit and establishes a material information binding relationship. S2. The status detection component collects the status of each material storage location in the cache storage module, and the storage mapping submodule constructs or updates the virtual storage structure in real time based on the collection results. S3. The matching decision submodule executes the target storage location matching logic based on the current virtual storage structure state and the preset priority strategy; S4. The instruction generation submodule generates control instructions, including path, clamping action and abnormal strategy, based on the target position coordinates and the motion characteristics of the automatic transfer module, and sends them to the mobile unit for execution; S5. The material handling execution component performs handling and placement operations, and the status detection component confirms the material's arrival status; S6. After placement confirmation, the data update submodule updates the virtual storage structure, completes the binding of materials with storage locations, and records the batching execution log.

[0023] The automatic batching control method based on the automatic batching system for columnar materials of the present invention has the same beneficial effects as the automatic batching system for columnar materials, which will not be repeated here. This method further standardizes the system's operation process, enabling the batching operation to have stronger logical closed-loop performance, fault tolerance, and information traceability, thereby improving the intelligence level and operational stability of the entire batching process. Attached Figure Description

[0024] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a general framework diagram of the automatic batching system of the present invention; Figure 2 This is a schematic diagram of the cache storage module of the present invention; Figure 3 This is a flowchart of the ingredient control method of the present invention. Figure 4 This is a flowchart of the matching decision submodule of the present invention.

[0026] In the diagram: 1. Automatic transport module; 2. Transport execution component; 3. Cache storage module; 4. Central control module; 5. Communication submodule; 6. Management submodule; 7. Storage mapping submodule; 8. Instruction generation submodule; 9. Status detection component. Detailed Implementation

[0027] To make the objectives, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0028] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0029] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0030] Example 1 Reference Figure 1 and Figure 3 This is the first embodiment of the present invention, which provides an automatic batching system for columnar materials. This system enables the automatic generation, handling, and buffering of columnar material units. It includes: a material generation module (not shown in the figure), an automatic transfer module (not shown in the figure), a buffer storage module, and a central control module. The material generation module processes raw materials to form columnar material units; the automatic transfer module handles the grabbing, moving, and dispensing of material units; the buffer storage module provides orderly storage and status feedback for the material units; and the central control module coordinates the operation of various functional modules within the system, ensuring closed-loop automated control of the batching process.

[0031] Specifically, the material generation module includes an extrusion molding device and a cooling and shaping component, used to extrude pretreated raw materials into cylindrical units with a uniform cross-section and then cool and solidify them. The automatic transfer module includes a magnetic navigation guide path positioned between the material generation module and the buffer area. A programmable automatic moving unit runs on this path, and a handling execution component is mounted on the automatic moving unit. The handling execution component includes a lifting mechanism, a multi-axis robotic arm, and a gripping device, used to grasp, rotate, and place the cylindrical material units.

[0032] Furthermore, the cache storage module is configured as a three-dimensional storage rack structure, including multiple clearly separated material storage locations. Each storage location is equipped with a photoelectric sensor as a status detection component, which is installed on the top or side wall of the location to collect the occupancy status and material specification information of the location in real time, and transmit the detection data to the central control module through a communication link.

[0033] The central control module includes a communication submodule, a management submodule, a storage mapping submodule, a matching decision submodule, an instruction generation submodule, and a data update submodule. The communication submodule receives material generation signals from the material generation module; the management submodule generates and binds a unique identifier to each columnar material unit; the storage mapping submodule constructs a virtual storage structure model based on detection data; the matching decision submodule matches the target location from available storage locations according to set rules (such as location distance priority, cache load balancing, etc.); the instruction generation submodule generates the transport path and control instructions accordingly; and the data update submodule updates the virtual structure in real time after transport is completed and records relevant batching operation data, achieving a data closed loop throughout the entire process.

[0034] The system continuously manufactures columnar material units through a material generation module. Upon completion, the generation information is reported to the central control module via a communication submodule. After receiving the material generation signal, the moving unit in the automatic transfer module begins operation, and the material handling execution component performs the grabbing operation of the material unit. Simultaneously, the status of each storage location in the cache storage module is collected by the status detection component and fed back to the central control module. The central control module establishes a virtual cache structure through the storage mapping submodule, and the matching decision submodule matches the target storage location based on the real-time cache status and a preset strategy. The instruction generation submodule generates the corresponding handling path and execution action control instructions, which are then sent to the automatic moving unit to execute the handling action. After handling is completed, the status detection component sends back material arrival information, and the data update submodule completes status updates, identifier binding, and data recording, ensuring full tracking and controllable management of the batching process.

[0035] In summary, by setting up a material generation module, an automatic transfer module, a cache storage module, and a central control module for coordinated use, the automated batching process for columnar material units can be completed efficiently. This solves the problems of low efficiency, poor accuracy, and difficulty in tracking that exist in traditional manual handling, and improves the system's intelligence level and production management capabilities.

[0036] Example 2 Reference Figure 1 This is a second embodiment of the present invention, which provides a status detection component for identifying the buffer status of columnar material units. The component includes a sensing device installed on the top, side wall, or bottom of each material storage location. The sensing device includes at least one photoelectric sensor, a visual recognition unit, a pressure detection module, or a laser ranging module, used to detect the occupancy status, material type, and abnormal conditions of the storage location from different dimensions, and to send the data to a central control module in real time.

[0037] Specifically, a visual recognition unit identifies the surface label information of the columnar material units, which, together with a pressure detection module, determines the material weight and placement. A laser ranging module determines whether the placement height meets the standard, and a photoelectric sensor determines whether the position is empty. All detection information is transmitted through an industrial communication link, ensuring the timeliness and integrity of data processing by the central control module.

[0038] Working principle: After the columnar material is transported to the target storage location, the status detection component uses multiple sensors to collaboratively determine whether the location is occupied, whether the material is placed in place, and its specifications and attributes, and uploads the data to the central control module in real time to update the storage mapping.

[0039] In summary, the multi-dimensional state detection design enables the system to have stronger identification capabilities and fault tolerance under conditions such as high-frequency handling and batch storage, avoiding duplicate dispensing or abnormal placement.

[0040] Example 3 Reference Figure 1 This is the third embodiment of the present invention. Unlike the previous embodiments, this embodiment provides a handling and execution component that integrates a multi-degree-of-freedom robotic arm. The robotic arm is mounted on a moving unit and includes a lifting mechanism, a rotating clamping structure, and a positioning correction mechanism.

[0041] Specifically, the lifting mechanism achieves vertical height adjustment through an electric screw lifting platform; the rotating clamping structure includes two openable and closable jaws and a motor-driven rotating ring for precise control of the posture of columnar materials; the positioning correction mechanism is located at the end of the clamping mechanism, which, combined with laser positioning and micro-adjustment devices, achieves automatic posture correction before placement.

[0042] Working principle: During the material handling process, after the robotic arm completes the grasping action, it adjusts its height and posture according to the target position coordinates, and ensures the delivery accuracy through the positioning correction mechanism before the material is delivered to prevent collisions and deviations.

[0043] In summary, this material handling assembly greatly improves handling accuracy and stability, and is particularly suitable for handling irregularly shaped or columnar material units with strict requirements on placement posture.

[0044] Example 4 Reference Figure 4 This is the fourth embodiment of the present invention, which provides a configurable priority matching strategy matching decision submodule. The module supports multi-rule combination decisions, including but not limited to location distance priority, material specification classification, cache load balancing, center-of-gravity hierarchical allocation, and order-oriented reservation.

[0045] Specifically, the matching strategy adopts a hierarchical setting method, allowing users to configure different priority combinations according to actual production needs and enable, adjust or disable them in real time through the interface, thereby realizing online updates and switching of the ingredient matching strategy.

[0046] Working principle: During the target location matching process, the system filters matching locations sequentially according to priority. If there are multiple candidate targets under a high-priority rule, a secondary rule is automatically introduced for further filtering until a unique target location is obtained.

[0047] In summary, the strategy module that supports flexible matching can be widely adapted to various types of orders and complex site layouts, thereby improving the intelligent scheduling capability of the batching system.

[0048] Example 5 This is the fifth embodiment of the present invention, which provides a virtual storage mapping system with a node-based dynamic database structure for implementing a storage mapping submodule in a central control module. The database structure uses each material storage location as an independent node, and each node includes: location number, three-dimensional coordinates, current status label, bound material identifier, material specification parameters, batch number, availability level, and update timestamp.

[0049] Specifically, the cache location status information collected by the status detection component will be periodically compared with the virtual database. If there is an inconsistency, the system will automatically trigger the status refresh mechanism to ensure that the system's logical state is synchronized with the actual physical state.

[0050] Working principle: Whenever materials are placed or retrieved, the database node fields are updated immediately, and the current operation time and related material information are recorded, realizing full-domain mapping and dynamic management of the cache area.

[0051] In summary, this virtual structure can significantly improve information synchronization accuracy and response speed, and avoid scheduling errors or path conflicts caused by data lag.

[0052] Example 6 This is the sixth embodiment of the present invention. Unlike the previous embodiments, this embodiment provides an instruction generation mechanism that includes complete handling control parameters. The instruction is output by the instruction generation submodule within the central control module and includes the following parameters: three-dimensional coordinates of the handling target, path trajectory node sequence, clamping method and force, lifting and lowering range, rotation angle setting, and fault tolerance retry threshold.

[0053] Specifically, the instructions are sent to the mobile unit controller via industrial communication protocols (such as Modbus TCP or Profinet) and have the functions of task interruption, pause and resumption.

[0054] The system generates a standard control instruction set based on the current task status, which is then parsed and executed by the controller. When a task is interrupted, the task status can be saved, and the unfinished part can be continued after the instructions are restored, thus avoiding duplicate work.

[0055] In summary, this embodiment ensures the stability and flexible control of the handling process, and enhances the system's adaptability to unexpected situations.

[0056] Reference Figure 3 This is the seventh embodiment of the present invention, which provides an automatic batching control method based on the batching logic of a central control module, including the following steps: S1: The communication submodule receives material generation information, and the management submodule binds a unique identifier; S2: The status detection component collects cached status, and the storage mapping submodule constructs a virtual structure; S3: The matching decision submodule matches the target position; S4: The instruction generation submodule issues control instructions; S5: The handling execution component completes material handling and placement; S6: The data update submodule updates the virtual structure and records logs.

[0057] Working principle: The entire process forms a complete closed loop. From material generation to warehousing operations, the control system automatically manages everything, ensuring efficient system operation and complete traceability.

[0058] In summary, this method improves ingredient dispensing efficiency and data integrity, ensuring that all ingredient dispensing activities are completed under unified instructions and status control.

[0059] Example 8 This is the eighth embodiment of the present invention, which further optimizes the matching logic process by using a progressive filtering method to match the target storage location: Specifically, the matching decision submodule first executes the first-level priority rule filtering. When there are multiple target positions that meet the conditions, secondary rules are introduced to continue filtering until a unique target position is locked. If no match is found after all rules have been executed, the default allocation strategy is activated.

[0060] This process ensures that priority control is reflected layer by layer in actual operation, while retaining a default fallback mechanism in extreme scenarios to avoid command generation failure.

[0061] In summary, this matching strategy improves the intelligence and stability of the ingredient batching task, making it adaptable to complex production environments.

[0062] Example 9 This is the ninth embodiment of the present invention, which focuses on the data update process after the ingredients are prepared: Once the status detection component confirms that the material is in place, the data update submodule immediately establishes a binding relationship between the material and the storage location and writes it to the database. At the same time, it updates the status of the corresponding node to "occupied" and generates material batching record information. The record fields include: unique identifier, location number, completion time, handling result, exception information, and execution instruction number.

[0063] This data management mechanism ensures the traceability of every system operation, providing data support for subsequent scheduling analysis and anomaly investigation.

[0064] In summary, the structuring and standardization of data records enhances the transparency and management capabilities of the ingredient mixing system.

[0065] Example 10 This is the tenth embodiment of the present invention, which handles the dynamic rescheduling situation during the transportation process: When the virtual memory structure reports a change in the target location status, the system executes the following process sequentially: a. Trigger an interrupt and record the event; b. Refresh storage status; c. Rematch the target bits; d. Generate new transport instructions; e. Perform the updated transport operation; f. The data update module records new states and abnormal events.

[0066] This process can avoid transport failures caused by temporary changes in the target location and improve the system's self-healing ability in case of anomalies.

[0067] In summary, this dynamic scheduling process ensures that the system has a high degree of flexibility and adaptability, making it particularly suitable for scenarios where material storage changes frequently.

[0068] The automatic batching system for columnar materials provided by this invention constructs a closed-loop automated system covering the entire process of "processing-handling-caching-management" through the coordinated cooperation of the material generation module, automatic transfer module, buffer storage module and central control module, aiming to improve the efficiency, accuracy and intelligence level of batching of columnar materials.

[0069] First, the material generation module processes the raw materials, forming cylindrical material units with fixed dimensions and specifications using methods such as molding, extrusion, or injection molding. Upon completion, it outputs a material generation signal and material parameter information. This signal is received by the communication submodule in the central control module and serves as a trigger signal for task initiation.

[0070] The management submodule in the central control module assigns a unique identifier to each columnar material unit based on the received material parameters and binds it to the corresponding material information, including specifications, batch number and generation time, to ensure that the subsequent handling and management processes have a basis for information traceability.

[0071] While materials are being prepared, each material storage location in the cache storage module collects its occupancy status and environmental information in real time through status detection components (such as photoelectric sensors, pressure modules, and visual recognition devices), and uploads the detection results to the central control module. The storage mapping submodule then constructs and updates the virtual storage structure. This virtual structure exists in the form of a node-based database, continuously reflecting the physical cache status and providing an accurate basis for handling decisions.

[0072] During the target location selection process, the matching decision submodule, based on the current material characteristics and cache structure status, executes the selection process step by step using a configurable and scalable multi-level priority matching strategy to determine the optimal storage target location. The strategy can be based on factors such as location distance, material classification, cache load, center of gravity control, and order reservation, offering high flexibility and adaptability.

[0073] Once the target location is determined, the instruction generation submodule generates control instructions containing information such as path trajectory, clamping parameters, rotation angle and fault tolerance mechanism based on the target coordinates and path environment, and sends them to the automatic transfer module through industrial-grade communication protocol.

[0074] The mobile unit in the automated transfer module begins performing the handling task, controlling its multi-degree-of-freedom robotic arm to grasp, move, and place cylindrical materials. The robotic arm adjusts its height via a lifting mechanism, adjusts its posture via a rotating clamping structure, and fine-tunes the lateral deviation and tilt angle before placement by a positioning correction mechanism to ensure accurate material placement.

[0075] After the material handling task is completed, the status detection component checks the target location again and sends a material arrival signal back to the central control module. The data update submodule then updates the virtual storage structure node status accordingly, binds the material identifier to the storage location, and generates and stores a complete batching operation log.

[0076] If a sudden change or abnormal situation occurs at the target location during the transfer process, the system will immediately trigger a dynamic rescheduling mechanism to pause the current task, refresh the storage status, re-match the target location, and generate new control commands to ensure the smooth recovery and execution of the task.

[0077] The overall system architecture adopts an information-driven and task-response parallel mechanism to achieve efficient scheduling, precise control and full-process tracking of material batching operations, and builds an intelligent, modular and scalable automatic batching solution for columnar materials.

[0078] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. An automatic batching system for columnar materials, comprising: a material generation module for processing raw materials to form columnar material units; characterized in that: include: The automatic transfer module includes a guide path disposed between the material generation module and the buffer area, a moving unit running along the guide path, and a handling execution component installed on the moving unit. The handling execution component is used to complete the gripping, moving, and delivery of the columnar material unit. The cache storage module has multiple material storage locations, and each material storage location is equipped with a status detection component to collect the occupancy status and material information of that location. A central control module is used to coordinate the joint operation of the material generation module, the automatic transfer module, and the cache storage module. The central control module includes: The communication submodule is used to collect production information of the columnar material unit; The management submodule is used to generate and bind unique identifiers to each columnar material unit; The storage mapping submodule is used to establish and update the virtual mapping structure of the cache storage module; The matching decision submodule is used to select a matching storage target from multiple free locations based on at least one preset rule; The instruction generation submodule is used to generate path and motion control instructions for driving the automatic transfer module to perform handling operations; The data update submodule is used to update the virtual storage structure status after the materials have been moved and to record the batching operation data. The automatic transfer module, the cache storage module, and the central control module form a collaborative closed loop for the automated processing of the entire process of processing, handling, caching, and information management of the columnar material unit.

2. The automatic batching system for columnar materials according to claim 1, characterized in that, The status detection component includes at least one of the following sensing devices: photoelectric sensor, visual recognition unit, pressure detection module, and laser ranging module. It is installed at the top, side wall, or bottom of the material storage location and is used to detect from multiple dimensions whether the storage location is vacant, occupied, or in an abnormal state. The detection results are fed back to the central control module in real time via communication.

3. The automatic batching system for columnar materials according to claim 2, characterized in that, The transport execution component includes a multi-degree-of-freedom robotic arm mounted on the mobile unit, the robotic arm comprising: The lifting mechanism is used to achieve vertical height adjustment; A rotating clamping structure is provided at the end of the lifting mechanism to realize the clamping and rotational adjustment of the columnar material unit; A positioning correction mechanism is located at the end of the clamping structure and is used to correct the lateral or orientation deviation of the columnar material unit in real time during the placement process.

4. The automatic batching system for columnar materials according to claim 3, characterized in that, The matching decision submodule employs a multi-level, configurable priority matching strategy and supports dynamic weight adjustment. The strategy includes: Priority rules based on location distance; Classification rules based on the concentration of material specifications; Load balancing rules based on cache levels; Gravity stratification rules based on material weight; Targeted reservation rules based on order tags; Each rule can be enabled individually or executed in combination, and online switching and policy updates are supported to adapt to various production scenarios.

5. The automatic batching system for columnar materials according to claim 4, characterized in that, The virtual storage structure constructed by the storage mapping submodule is a node-based dynamic database. Each node contains the following fields: location number, three-dimensional coordinates, current status label, bound material identifier, material specification parameters, batch number, availability level, and update timestamp. The database is periodically compared with the data of the status detection component to ensure information synchronization.

6. The automatic batching system for columnar materials according to claim 5, characterized in that, The transport instructions issued by the instruction generation submodule include the following control parameters: Three-dimensional coordinates of the target location; Path trajectory node sequence; Clamping method and force parameters; The range of vertical movement; Rotation angle setting; Fault tolerance retry threshold; The instructions are sent to the motion controller of the mobile unit via an industrial-grade communication protocol and have task interruption and recovery functions.

7. An automatic batching control method for an automatic batching system for columnar materials according to claim 1, characterized in that, Includes the following steps: S1. The central control module receives material generation signals and material parameter information from the material generation module through the communication submodule, and the identification management submodule assigns a unique identifier to each columnar material unit and establishes a material information binding relationship. S2. The status detection component collects the status of each material storage location in the cache storage module, and the storage mapping submodule constructs or updates the virtual storage structure in real time based on the collection results to synchronously reflect the physical cache status. S3. The matching decision submodule performs target storage location matching logic based on the current virtual storage structure state and preset priority strategy, and selects a target location that is compatible with the current columnar material unit; S4. The instruction generation submodule generates a transport control instruction, including path, clamping action, pose control and abnormal strategy, based on the target position coordinates and the motion characteristics of the automatic transfer module, and sends it to the mobile unit for execution. S5. The handling execution component completes the handling and placement operation of the columnar material unit according to the received control command, and the status detection component confirms the material's arrival status; S6. After placement confirmation, the data update submodule updates the status information of the corresponding node in the virtual storage structure, binds the material identifier to the target location, and records a complete batching execution log for the traceability and data closed-loop management of the batching process.

8. The method according to claim 7, characterized in that, The matching process in step S4 is a progressive screening process. The matching decision submodule first performs an initial screening according to the highest priority rule. When there are multiple target positions that meet the conditions, the next level of priority rule is introduced to refine the screening until a unique target position is matched. If no match is found after all rules have been executed, the default allocation strategy is executed to complete the instruction generation.

9. The method according to claim 7, characterized in that, In step S6, after the state detection component confirms that the columnar material unit has been successfully placed in the target storage location and outputs a positioning confirmation signal, the data update submodule performs the following operation: Establish a one-to-one binding relationship between the unique identifier of the columnar material unit and the location information of the target storage location, and write the binding relationship into the storage database; Synchronously update the occupancy status, binding identifier, and availability attributes of the corresponding nodes in the virtual storage structure; Generate and archive the batching record information corresponding to the batching operation; wherein, the batching record information includes at least one or more of the following fields: unique identifier of columnar material unit, target storage location number, batching completion time, handling execution result status, anomaly marker information and execution instruction identifier, which are used to support subsequent production traceability, scheduling analysis and anomaly review.

10. The method according to claim 7, characterized in that, During the transfer process in step S5, if the virtual storage structure reports a change in the status of the current target storage location and it no longer meets the availability conditions, the following dynamic rescheduling process is executed: a. The central control module immediately triggers the handling task interruption process, suspends the current handling action of the automatic transfer module, and records the interruption event identifier and triggering reason; b. The storage mapping submodule refreshes the status information of all storage locations and reconstructs the virtual storage structure in real time to reflect the latest physical cache status; c. The matching decision submodule re-executes the target location matching logic based on the updated virtual storage structure to obtain new available target locations; d. The instruction generation submodule regenerates the handling control instruction based on the new target position parameters and sends it to the automatic transfer module in real time via the communication link; e. The transport execution component continues to perform the transport and placement operations of the columnar material unit according to the updated transport instructions; f. The data update submodule completes placement confirmation, status update, identifier binding, and abnormal process recording, which is used for autonomous response control and abnormal recovery closed-loop management during the handling process.

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