Material transfer device and control method thereof

Abstract

The invention provides a material transfer device and a control method thereof.The material transfer device comprises a rack arranged on a mounting base plane; the conveyor is mounted on the rack and is used for conveying materials; the recognition system is arranged at the conveying starting end of the conveyor and used for collecting and recognizing appearance feature information of the materials; the reversing mechanism is arranged on the conveyor, located on the downstream of the recognition system and used for changing the conveying direction of the materials according to the recognition result; and the sorting mechanism is arranged at the tail end of the conveyor, at least comprises two sorting channels which are arranged side by side, and is used for receiving and guiding the materials guided by the reversing mechanism to enter different next working procedures. Automatic and efficient sorting, screening and transferring operation of materials can be achieved through the conveyor, the recognition system and the reversing mechanism which are integrally arranged, the transferring efficiency of the materials is improved, and more time and labor are saved.

Description

Technical Field

[0001] This application relates to the field of material transfer technology, and in particular to a material transfer device and its control method. Background Technology

[0002] In modern industrial production, especially in food processing, pharmaceutical packaging, and electronic component assembly, material sorting and transfer are crucial links connecting upstream and downstream processes. Traditional material transfer methods rely heavily on manual visual inspection and sorting, which is not only inefficient and labor-intensive, but also prone to mis-inspection and omission due to human visual fatigue and subjective judgment differences, seriously affecting the final quality of products and production consistency.

[0003] With the development of automation technology, some automatic sorting equipment has emerged on the market. However, most existing equipment has limited functionality; for example, it can only screen materials by volume and cannot achieve fine sorting based on multiple dimensions such as color, shape, or surface defects. Furthermore, in the post-sorting transfer stage, materials are prone to secondary damage due to collisions or accumulation, especially for materials with high surface finish requirements, such as food and pharmaceuticals. How to achieve efficient and flexible transfer is a problem that urgently needs to be solved by those skilled in the art. For example, Chinese patent document CN107954187A discloses a material conveying and sorting device, but its structure is complex and the sorting channel design is relatively simple, making it unable to be flexibly adjusted according to material characteristics and exhibiting poor adaptability.

[0004] Therefore, how to provide a material transfer device with high integration, accurate identification, and convenient sorting to solve the above problems has become a research hotspot in this field. Summary of the Invention

[0005] This application provides a material transfer device and its control method, which can realize the automatic identification, precise reversal and efficient sorting of materials, and realize efficient and safe screening operations for various materials.

[0006] To achieve the above objectives, the embodiments of this application adopt the following technical solutions: This application provides a material transfer device, including a frame mounted on a mounting base; a conveyor mounted on the frame for conveying materials; an identification system located at the starting end of the conveyor for collecting and identifying the appearance characteristics of the materials; a reversing mechanism located on the conveyor and downstream of the identification system for changing the conveying direction of the materials according to the identification results; and a sorting mechanism located at the end of the conveyor, including at least two parallel sorting channels for receiving and guiding the materials guided by the reversing mechanism into different next processes, such as different packaging lines or collection containers.

[0007] The identification system includes a gantry bracket mounted on a frame, and a high-definition industrial camera and a light source fixed to the crossbeam of the gantry bracket. The lens of the high-definition industrial camera is vertically or tilted toward the surface of the conveyor belt of the conveyor to acquire material images.

[0008] The reversing mechanism includes a drive unit fixed to the side of the frame and a swing arm that is driven to the output shaft of the drive unit; the drive unit is a servo motor or a stepper motor, which can drive the swing arm to swing back and forth in the horizontal plane to push the material on the conveyor to the predetermined sorting channel.

[0009] This invention can achieve automatic and efficient sorting, screening and transfer of materials by integrating a conveyor, identification system and reversing system, which greatly improves the material transfer efficiency and saves more time and effort.

[0010] The driving component is a servo motor. The swing arm is hinged to the output shaft of the servo motor. The output shaft of the servo motor can swing the swing arm within a range of 0-90° to push the material on the conveyor to the predetermined sorting channel.

[0011] The sorting mechanism includes at least two chutes arranged side by side. The inlet end of the chutes is connected to the end of the conveyor to receive materials. The outlet end of the chutes extends downward at an angle to guide the materials to downstream collection equipment.

[0012] At least one chute has a detachable bottom plate with an installation groove. A screening plate is embedded in the installation groove, and the screening plate has screen holes evenly distributed to screen out mixed debris or small foreign objects during the material sliding process.

[0013] The screening plate is made of stainless steel or high-hardness wear-resistant plastic. The shape of the screen holes is round, rectangular, or grid-like, and their size is set according to the average particle size of the material to be sorted.

[0014] The conveyor is a belt conveyor, and the belt is made of food-grade PVC or PU material with anti-slip textures or baffles on the surface.

[0015] A control method for a material transfer device includes the following steps: Start the conveyor, and the material moves forward at a constant speed on the conveyor; The identification system collects image information of passing materials and transmits the image information to the controller; The controller processes the image information according to a preset sorting algorithm, identifies at least one feature of the material, including its size, color, shape, or surface defects, and generates control commands. When the material reaches the working area of ​​the reversing mechanism, the controller drives the reversing mechanism to move according to the control command, and diverts the material to the corresponding sorting channel; The material slides down the sorting channel to the corresponding next process or collection box, completing one sorting cycle.

[0016] The sorting algorithm is based on a deep learning model, which is trained using a large number of pre-collected material sample images to improve the accuracy of identifying materials with different characteristics.

[0017] The controller detects the material reaching the trigger position of the reversing mechanism using photoelectric sensors installed on the side of the conveyor, and calculates and controls the start-up timing and swing angle of the drive components in real time based on the conveyor's running speed and the material position.

[0018] As can be seen from the above technical solutions, the embodiments of this application have at least the following beneficial effects: 1. The material transfer device and control method provided in this application integrate material conveying, identification, reversing and sorting, realizing fully automated operation, greatly replacing manual sorting, and reducing unnecessary labor costs and management difficulties.

[0019] 2. By introducing a high-definition industrial camera and combining it with deep learning algorithms, this application can perform multi-dimensional and refined identification of materials, effectively eliminate defective products, and ensure the quality uniformity and yield rate of the final product.

[0020] 3. This application can use a swing arm driven by a servo / stepper motor for reversing, with precise movements and controllable force. Compared with methods such as air blowing or mechanical impact, it can effectively avoid damage to materials during the transfer process, and is especially suitable for materials with fragile surfaces.

[0021] 4. This application can simultaneously perform multi-level sorting by setting up multiple parallel sorting channels, such as dividing materials into superior, qualified, and substandard products. The replaceable screening plate design allows the device to flexibly adapt to the impurity removal needs of different types of materials, making it a multi-purpose machine and improving its versatility and utilization rate.

[0022] 5. This application integrates the identification, reversing, and sorting functions along the conveying direction, resulting in a compact structure, small footprint, and ease of embedding or modification into existing production lines, thereby improving the overall automation level of the production line.

[0023] It should be understood that the descriptions of technical features, technical solutions, beneficial effects, or similar language in the embodiments of this application do not imply that all features and advantages can be achieved in any single embodiment. Rather, it is understood that the description of a feature or beneficial effect means that a specific technical feature, technical solution, or beneficial effect is included in at least one embodiment. Therefore, the descriptions of technical features, technical solutions, or beneficial effects in this specification do not necessarily refer to the same embodiment. Furthermore, the technical features, technical solutions, and beneficial effects described in this embodiment can be combined in any suitable manner. Those skilled in the art will understand that embodiments can be implemented without one or more specific technical features, technical solutions, or beneficial effects of a particular embodiment. In other embodiments, additional technical features and beneficial effects may be identified in specific embodiments that do not embody all embodiments. Attached Figure Description

[0024] Figure 1 A schematic diagram of a material transfer device provided in an embodiment of this application in a specific embodiment; Figure 2 This is an isometric side view of the material transfer device; Figure 3 This is a schematic diagram of the material transfer device from another perspective. Figure 4 This is a front view of the material transfer device; Figure 5 This is a top view of the material transfer device; Figure 6 This is a flowchart of the control method for a material transfer device.

[0025] Reference numerals: 100, frame; 200, conveyor; 300, identification system; 310, gantry bracket; 320, high-definition industrial camera; 400, reversing mechanism; 410, driving component; 420, swing arm; 500, sorting mechanism; 510, sorting channel; 511, chute; 512, mounting slot; 520, screening plate. Detailed Implementation

[0026] The terms "first," "second," and "third," etc., used in this application specification and accompanying drawings are used to distinguish different objects, not to limit a specific order.

[0027] In the embodiments of this application, the terms "exemplary" or "for example" are used to indicate that something is an example, illustration, or description. Any embodiment or design that is described as "exemplary" or "for example" in the embodiments of this application should not be construed as being more preferred or advantageous than other embodiments or design. Specifically, the use of the terms "exemplary" or "for example" is intended to present the relevant concepts in a specific manner.

[0028] This application provides a material transfer device, including a frame 100, which serves as the supporting foundation for the entire device and is placed directly on the installation base surface in the workshop. A conveyor 200 is mounted on the frame 100 for carrying and transporting materials to be processed. Along the material conveying direction, an identification system 300, a reversing mechanism 400, and a sorting mechanism 500 are arranged sequentially. The identification system 300 is located at the beginning of the conveying process and is responsible for capturing the appearance information of the materials passing beneath it. The reversing mechanism 400 is located downstream of the identification system 300 and guides the conveying direction of specific materials according to the instructions given by the identification system 300. The sorting mechanism 500 is located at the end of the conveyor 200 and includes at least two parallel sorting channels 510 for smoothly diverting the materials guided by the reversing mechanism 400 to different next processes, such as different packaging lines or collection containers.

[0029] To achieve high-precision image acquisition, the recognition system 300 is designed with a gantry bracket 310 mounted on the frame 100, spanning above the conveyor 200. A high-definition industrial camera 320 and a light source for supplementing the camera are fixed on the crossbeam of the gantry bracket 310. The camera lens is aimed at the surface of the conveyor belt to ensure that images of each material can be clearly captured.

[0030] To ensure precise, rapid, and smooth reversing action, the reversing mechanism 400 consists of a drive unit 410 fixed to the side of the frame 100 and a swing arm 420 connected to the motor shaft. The drive unit 410 uses a fast-response servo motor or stepper motor, which can precisely drive the swing arm 420 to swing in the horizontal plane according to the control signal, so as to gently push the material from the conveyor belt to the predetermined sorting channel 510 inlet.

[0031] Another embodiment of the drive unit 410 is that the drive unit 410 is a servo motor, and the swing arm 420 is hinged to the output shaft of the servo motor. The output shaft of the servo motor can swing the swing arm 420 within the range of 0-90° to push the material on the conveyor 200 to the predetermined sorting channel 510.

[0032] To meet the sorting requirements of different materials, the sorting mechanism 500 consists of at least two parallel chutes 511. The inlets of these chutes 511 are smoothly connected to the end of the conveyor 200, and the material enters the chutes 511 under the action of inertia. The outlet end of the chutes 511 is inclined downward, and the material is conveyed by its own weight, requiring no additional power, and has a simple structure and low energy consumption.

[0033] In a preferred embodiment, for materials that are prone to contamination with debris or require the removal of minute impurities, at least one of the chute 511 has a detachable base plate. The base plate has an mounting groove 512 into which a screening plate 520 can be installed. The screening plate 520 has screen holes of a specific shape and size processed according to the material characteristics. When the material slides down the chute 511, debris, powder, or small-sized defective products mixed in will fall through the screen holes, thereby achieving secondary cleaning of the material.

[0034] Considering the hygiene requirements of the food and pharmaceutical industries, the screening plate 520 is preferably made of easy-to-clean, corrosion-resistant stainless steel or high-hardness, wear-resistant plastic. The shape of the screen holes can be circular, rectangular, or grid-like, and their specific dimensions need to be customized according to the average particle size of the material to be sorted and the impurity removal requirements to achieve the best screening effect.

[0035] To ensure smooth conveying and material hygiene, conveyor 200 is preferably a belt conveyor, with the belt made of food-grade PVC or PU material. The belt surface is also designed with anti-slip textures, or baffles are added according to the shape of the material to prevent the material from slipping or rolling during conveying.

[0036] The present invention also provides a control method for the above-mentioned material transfer device. The method includes: starting the conveyor 200 so that the material passes through each station in sequence; the identification system 300 collects material images and transmits them to the controller; the controller has a built-in intelligent algorithm to process the images, identify the size, color, shape or surface defects of the material, and generate sorting instructions accordingly; when the material arrives at the working area of ​​the reversing mechanism 400 with the conveyor 200, the controller drives the reversing motor and the swing arm 420 to move, accurately pushing the material into the corresponding sorting channel 510; finally, the material slides down through the sorting channel 510, completing the sorting and transfer.

[0037] To improve the accuracy and robustness of identification, the sorting algorithm used in the controller can be based on a deep learning model. This model is trained by collecting tens of thousands of images of materials with different characteristics in advance, enabling it to cope with complex and ever-changing real-world situations and effectively distinguish between qualified products and various types of defective products.

[0038] To achieve precise timing triggering, a photoelectric sensor can be installed on the side of the conveyor 200 near the reversing mechanism 400. The controller receives the trigger signal from the sensor and, combined with the known speed of the conveyor 200 and the relative distance between the material and the reversing mechanism 400, calculates the optimal start time of the drive component 410 and the swing angle of the swing arm 420 through a precise algorithm, ensuring that every material feeding action is accurate.

[0039] Example 1 like Figures 1-3As shown, this embodiment provides a material transfer device, mainly used for the automatic sorting and transfer of small materials such as nuts, candies, or electronic components. The device includes a frame 100 welded from stainless steel square tubing, with adjustable feet installed at the bottom of the frame 100 to ensure it is placed stably on the workshop floor.

[0040] A belt conveyor 200 is fixedly mounted on the frame 100. The belt conveyor 200 consists of a conveyor belt, a drive roller, a driven roller, and a geared motor. The conveyor belt is made of food-grade PU material with a slightly anti-slip texture on the surface to prevent materials such as almonds from slipping during the conveying process.

[0041] like Figure 1 and Figure 4 As shown, a portal-shaped mounting bracket spans above the conveying start end of the belt conveyor 200. The mounting bracket is bolted to the frame 100. A high-definition industrial camera 320 and an LED ring light source are fixed to the crossbeam of the mounting bracket. The lens of the high-definition industrial camera 320 points vertically downwards, directly facing the surface of the conveyor belt. The LED ring light source surrounds the lens, providing a uniform, shadowless lighting environment for the camera, ensuring clear and high-contrast images of the captured materials. The camera is connected to a controller located in the electrical control box via a data cable.

[0042] Downstream of the identification system 300, near the middle to rear of the belt conveyor 200, a reversing mechanism 400 is installed. For example... Figure 1 and Figure 4 As shown, the reversing mechanism 400 includes a mounting base fixed to the side of the frame 100, on which a servo motor is fixed. The output shaft of the servo motor is vertically upward and passes through the mounting base. The top end of the output shaft is fixedly connected to one end of a swing arm 420 via a coupling. The swing arm 420 is a lightweight aluminum alloy rod, with a soft rubber sleeve on its free end to reduce impact when in contact with materials. The servo motor can drive the swing arm 420 to reciprocate from 0 to 90° in the horizontal plane according to the controller's instructions.

[0043] At the end of the belt conveyor 200, downstream of the reversing mechanism 400, a sorting mechanism 500 is installed. For example... Figure 1 and Figure 4 As shown, the sorting mechanism 500 includes a first chute and a second chute arranged side by side. Both chutes are made of bent stainless steel plates, with their inlet ends smoothly connected to the lower end of the belt conveyor 200 to receive materials falling from the conveyor belt. The chute 511 is inclined downward at approximately 30 degrees, and the material slides down the chute 511 to the outlet end under the action of gravity.

[0044] In this embodiment, the second chute is used to transport materials that may contain debris, therefore its bottom plate is designed to be detachable. Figure 1and Figure 5 As shown, the bottom plate of the second chute has a rectangular mounting groove 512, in which a screening plate 520 is embedded. The screening plate 520 is fixed in the mounting groove 512 by snaps around its perimeter, making it easy to remove, clean, and replace. The screening plate 520 is made of 304 stainless steel, and racetrack-shaped screen holes are uniformly stamped on the plate. The size of these screen holes is slightly smaller than the average particle size of the almond kernels in this embodiment. When the almonds roll in the chute 511, the mixed fine debris and dust will fall through the screen holes, while the whole almonds will slide from the outlet end into the downstream collection frame, thus achieving clean sorting. The bottom plate of the first chute is enclosed and is used to transport qualified products with smooth surfaces that do not require screening.

[0045] Example 2 This embodiment provides a control method for controlling the material transfer device described in Embodiment 1. For example... Figure 6 As shown, the method includes the following steps: Step S1: System Initialization and Startup. The operator sets sorting parameters, such as material type and premium product standards, through the HMI (Human Machine Interface) and starts the device. The PLC controller issues a command to start the geared motor of the belt conveyor 200, and the conveyor belt begins to run at a preset constant speed.

[0046] Step S2: Image Acquisition and Transmission. When the material moves along the conveyor belt to the shooting area of ​​the recognition system 300, the photoelectric sensor mounted on the gantry bracket 310 triggers the high-definition industrial camera 320. The camera captures a real-time image of the material and transmits the image data at high speed to the image processing unit, such as an embedded vision system integrated with a PLC or a standalone industrial computer, via an interface.

[0047] Step S3: Image Processing and Decision Making. The image processing unit calls a pre-trained deep learning model, such as a convolutional neural network model trained on the TensorFlow framework, to perform inference analysis on the image. This model has been trained on thousands of images containing qualified almonds, cracked almonds, almond fragments, and foreign objects such as stones, and can accurately identify key features of the material, such as color, size, and outline integrity. Based on the identification results, the system determines the material category, such as "premium grade," "second-grade," or "foreign object," and sends the corresponding sorting instructions to the PLC controller.

[0048] Step S4: Precise Reversing Control. The PLC controller continuously receives signals from the photoelectric sensor installed next to the reversing mechanism 400. When the sensor detects material obstruction, the high-speed counter inside the PLC records the moment. Based on the known conveyor belt speed, the fixed distance of the material from the detection point to the center point of the reversing mechanism 400, and the response time required for the swing arm 420 to complete its action from receiving the command, the PLC precisely calculates the optimal timing for the swing arm 420 to start. When the timer expires, the PLC sends a pulse train to the driver of the servo motor, controlling the servo motor to rotate precisely to a predetermined angle, for example, swinging 45 degrees when moving towards the second chute. The servo motor drives the swing arm 420 to move quickly and smoothly, guiding the material smoothly to the target sorting channel 510.

[0049] Step S5: Sorting and Collection. Premium grade products guided to the first chute slide directly down chute 511 into the premium grade collection box. Secondary grade products or foreign objects guided to the second chute, as they slide down chute 511, pass through the area embedded with the screening plate 520. Mixed debris, powder, and other minute impurities are separated through the screen holes and collected in the waste box below. The cleaned secondary grade products then slide from the outlet end of the second chute into the secondary grade collection box, completing the entire sorting and transfer process.

[0050] Step S6: Cycle and Stop. The controller repeats steps S2 to S5 until a stop command is received. The system safely shuts down when all materials have been processed or the emergency stop button is pressed.

[0051] The scope of protection of this invention is not limited to the specific embodiments described above. Any equivalent substitutions or modifications made within the spirit of this invention, such as replacing the belt conveyor 200 with a chain plate conveyor 200, replacing the servo motor with a stepper motor with a synchronous belt, or increasing the number of chutes 511 to three or more, should be considered to fall within the scope of protection of this invention.

[0052] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any changes or substitutions within the technical scope disclosed in this application should be covered within the scope of protection of this application.

Claims

1. A material transfer device, characterized in that... ,include: The frame (100) is mounted on the mounting base. A conveyor (200), mounted on the frame (100), is used for conveying materials; An identification system (300) is installed at the starting end of the conveyor (200) to collect and identify the appearance characteristics of the material; A reversing mechanism (400), disposed on the conveyor (200) and located downstream of the identification system (300), is used to change the conveying direction of the material according to the identification result; The sorting mechanism (500) is located at the end of the conveyor (200) and includes at least two sorting channels (510) arranged side by side for receiving and guiding the materials guided by the reversing mechanism (400) into different next processes.

2. The material transfer device according to claim 1, characterized in that... The identification system (300) includes a gantry bracket (310) mounted on the frame (100), and a high-definition industrial camera (320) and a light source fixed on the crossbeam of the gantry bracket (310). The lens of the high-definition industrial camera (320) is perpendicular or tilted toward the conveyor belt surface of the conveyor (200).

3. The material transfer device according to claim 2, characterized in that... The reversing mechanism (400) includes a drive member (410) fixed to the side of the frame (100) and a swing arm (420) that is drivenly connected to the output shaft of the drive member (410).

4. The material transfer device according to claim 3, characterized in that... The driving component (410) is a servo motor or a stepper motor, which can drive the swing arm (420) to swing back and forth in the horizontal plane.

5. The material transfer device according to claim 3, characterized in that... The drive unit (410) is a servo motor.

6. The material transfer device according to claim 5, characterized in that... The sorting channel (510) includes at least two parallel chutes (511), the inlet end of which is connected to the end of the conveyor (200); the outlet end of which extends downward at an angle.

7. The material transfer device according to claim 6, characterized in that... At least one of the slide grooves (511) has an installation groove (512) on its bottom plate, and a screening plate (520) is embedded in the installation groove (512), and the screening plate (520) has screen holes evenly distributed on it.

8. The material transfer device according to claim 7, characterized in that... The sieve holes are circular, elongated, or grid-like in shape.

9. The material transfer device according to claim 8, characterized in that... The conveyor (200) is a belt conveyor with anti-slip textures or baffles on its surface.

10. The control method for the material transfer device according to any one of claims 1-9, characterized in that... This includes the following steps: Start the conveyor (200) to transport materials; The identification system (300) collects image information of the passing materials and transmits the image information to the controller; The controller processes the image information according to a preset sorting algorithm, identifies at least one feature of the material, including its size, color, shape, or surface defects, and generates control commands. When the material reaches the working area of ​​the reversing mechanism (400), the controller drives the reversing mechanism (400) to move according to the control command, and pushes the material to the corresponding sorting channel (510); The material slides down through the sorting channel (510) to the corresponding next process or collection box, completing one sorting cycle.

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