Tray sorting method

Abstract

The invention discloses a charging tray sorting method which is realized based on charging tray sorting equipment, and through a series of steps of connection, sorting, weighing, appearance detection, qualified product conveying and defective product removal, cooperative operation of all mechanisms and precise regulation and control of a control system are combined, so that full-process automatic sorting of charging trays is realized. According to the tray sorting method, a traditional manual sorting mode is replaced, the sorting efficiency is greatly improved, the labor cost is reduced, meanwhile, the sorting precision is improved, errors caused by manual operation are effectively avoided, and the tray sorting method is suitable for large-scale tray sorting scenes.

Description

Technical Field

[0001] This invention relates to the technical field of automated equipment, and in particular to a method for sorting material trays. Background Technology

[0002] In existing technologies, the sorting process of material trays typically relies on manual operation, which suffers from low efficiency, high error rates, and high labor intensity. With the development of intelligent manufacturing, there is an urgent need for automated equipment to improve sorting efficiency, reduce costs, and ensure sorting accuracy.

[0003] In view of this, the present invention addresses the many shortcomings and inconveniences caused by the imperfections of existing material tray sorting methods, and has been developed through in-depth research, improvement and trial production. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a tray sorting method that can replace manual tray sorting, thereby improving tray sorting efficiency and reducing labor costs.

[0005] To achieve the above objectives, the solution of the present invention is: A method for sorting material trays, characterized in that it is based on a material tray sorting device, which includes: a connecting mechanism, a sorting mechanism, a transfer mechanism, a defective product channel, a roller conveyor line, a lifting mechanism, a discharge channel, and a control system. The connecting mechanism includes a connecting platform and a connecting robot. The connecting robot is installed on the connecting platform. The rear end of the connecting platform is connected to the AGV trolley, and the front end of the connecting platform is connected to the sorting platform of the sorting mechanism. The connecting robot is used to transfer the material box or tray between the AGV trolley, the connecting platform and the sorting platform. The connecting robot is equipped with a first camera and sensors. The sorting mechanism includes a sorting platform, a sorting robot, and a weighing module. The sorting platform is connected to the front end of the connecting platform. The sorting robot is installed on the sorting platform and is equipped with a second camera. The weighing module is located at the front end of the sorting platform and within the stroke range of the sorting robot. The transplanting mechanism includes a transplanting frame and a transplanting robot. The transplanting robot is installed on the top of the transplanting frame. The weighing module, one end of the defective product channel, and one end of the roller conveyor line are respectively located within the stroke range of the transplanting robot. The transplanting robot is equipped with a third camera, which is used to acquire the weighed material tray and determine whether the appearance of the material tray meets the requirements. The roller conveyor line is correspondingly set inside the transplanting frame. The roller conveyor line includes a roller support, an upper roller line and a lower roller line. The upper roller line and the lower roller line are spaced apart on the roller support. The lifting mechanism is installed at the front end and the rear end of the roller conveyor line respectively. The upper roller line is used to transport the pallet containing qualified material trays, and the lower roller line is used to transport the empty pallet in the opposite direction. The lifting mechanisms at both ends of the roller conveyor line are used to transplant the empty pallet from the lower layer to the upper roller line. The feeding channel is connected to the lifting mechanism at the rear end of the transplanting frame. The feeding channel and the adjacent lifting mechanism are connected by a robotic arm or a manual station to achieve the transfer of qualified material trays. Empty trays are transferred to the lower roller line through the lifting mechanism. The connecting robot of the connecting mechanism, the sorting robot of the sorting mechanism, the weighing module, the transplanting robot of the transplanting mechanism, the defective product channel, the roller conveyor line, the lifting mechanism, the unloading channel and the third camera are respectively connected to the control system. The tray sorting method includes the following steps: S1. Connecting and transferring: The AGV trolley transports the material box loaded with the material tray to the connecting platform of the connecting mechanism. The connecting roller on one side of the connecting platform transfers the material box towards the sorting mechanism. At the same time, the first camera and sensor on the connecting robot arm cooperate to obtain the position and existence information of the material tray in the material box. The connecting robot arm picks up the material box or material tray according to the information and transfers it to the sorting platform of the sorting mechanism. S2. Sorting and Transfer: The sorting rollers of the sorting platform work with the connecting rollers of the connecting platform to achieve stable transfer of the material box. The second camera on the sorting robot arm obtains the position information of the material tray on the sorting platform. The sorting robot arm adjusts the position through multi-axis guide rails and adjusts the angle through rotary cylinders to accurately grip the material tray and transfer it to the weighing module at the front of the sorting platform. S3. Weighing detection: The weighing module weighs the material tray and transmits the weight data to the control system. The control system determines whether the weight of the material tray meets the preset standard. S4. Appearance inspection: The third camera on the transplanting robot arm acquires an image of the appearance of the weighed material tray and transmits the image information to the control system. The control system analyzes the appearance image and determines whether the appearance of the material tray meets the preset requirements. S5. Sorting and diversion: The control system judges whether the material tray is qualified based on the weight detection result and the appearance inspection result. If the material tray is unqualified, the transfer robot will transfer it to the defective product channel, and the defective product channel will transport the defective material tray to the outside of the equipment. If the material tray is qualified, the transfer robot will transfer it to the empty tray of the upper roller line of the roller conveyor. S6. Pallet replenishment: The lower roller conveyor of the roller conveyor transports empty pallets in reverse. When the upper roller conveyor needs an empty pallet, the lifting mechanism lifts the empty pallet from the lower roller conveyor to the upper roller conveyor, thus completing the empty pallet replenishment. S7. Unloading and output: The pallet loaded with qualified material trays is transferred to the rear lifting mechanism through the upper roller conveyor. The pallet is then transferred to the unloading channel by a robotic arm or manual station, completing the final output of the qualified material trays. S8. Empty box recycling: After all the material trays in the box have been transferred, the sorting rollers of the sorting platform will transfer the empty box to the connecting rollers on the other side of the connecting platform. The connecting rollers on this side will transfer the empty box to the AGV trolley, and the AGV trolley will transport the empty box to the material tray loading area for reuse.

[0006] Furthermore, in step S1, the connecting rollers on both sides of the connecting platform move in opposite directions. One connecting roller transports the material box loaded with the material tray, while the other connecting roller transports the empty material box, thus achieving bidirectional synchronous transmission of the material box.

[0007] Furthermore, in step S1, the first camera captures images of the material tray distribution inside the material box in real time and transmits them to the control system. The control system analyzes the stacking state of the material trays through an image recognition algorithm. If the stacking of material trays is detected to be tilted or misaligned, the control system controls the multi-joint joints of the connecting robot arm to adjust the posture in coordination. The position of the material tray is gently corrected by the gripper of the mechanical claw before it is picked up, so as to avoid damage to the material tray during the picking process.

[0008] Furthermore, in step S3, before each weighing, the control system controls the sorting robot to transfer a standard weight to the weighing module for calibration. After calibration, the weight is reset, and the material tray is weighed again to ensure the long-term accuracy of the weighing data.

[0009] Furthermore, the control system records the sorting time, weighing data, appearance inspection results, and sorting path information of each material tray in real time, and generates a traceable sorting log. The log data is uploaded to the factory management system in real time for production scheduling and quality traceability.

[0010] Furthermore, the control system presets a qualified weight range for the material tray. When the weight of the material tray is within the qualified range, it is determined to be qualified. When the weight of the material tray exceeds the qualified range, it is directly determined to be an unqualified material tray, without the need for subsequent appearance inspection. The transfer robot directly transfers it to the defective product channel.

[0011] Furthermore, the conveying direction of the defective product channel is from inside the transplanting frame to outside the frame. The transplanting robot places the defective product tray on the defective product conveyor belt, and the defective product driving mechanism drives the conveyor belt to quickly transport the defective product tray outside the equipment to avoid mixing with qualified products.

[0012] Furthermore, the sorting platform has two sorting rollers on both sides corresponding to the connecting rollers of the connecting platform. The center of the sorting platform has a walking trough that is set along the movement direction of the sorting rollers. The walking trough extends to the weighing area at the front end of the sorting platform. The weighing module is installed on the weighing area. The sorting robot directly transfers the material tray to the weighing module along the walking trough without the need for transfer.

[0013] Furthermore, the docking robot includes a mounting base, a first robotic arm, a second robotic arm, and a robotic gripper. The mounting base is connected to the first robotic arm via a first joint, the second robotic arm is connected to the first robotic arm via a second joint, and the second robotic arm is connected to the robotic gripper via a third joint. The first joint, the second joint, and the third joint can all rotate 360°. The robotic gripper includes a clamp and two spaced-apart clamps. The clamp and clamps are perpendicular to each other. A sensor is provided on one side of the clamp, and a first camera is provided at the position between the two clamps corresponding to the position of the robotic gripper.

[0014] Furthermore, the defective product channel includes a defective product conveyor belt, a defective product conveying bracket, and a defective product driving mechanism. One end of the defective product conveying bracket is located inside the transplanting frame in front of the weighing module, and the other end protrudes to the outside of one side of the transplanting frame. The defective product conveyor belt is installed on the defective product conveying bracket, and the conveying direction is from inside the transplanting frame to outside the transplanting frame. The defective product driving mechanism is located on the defective product conveying bracket below the defective product conveyor belt and is connected to the defective product conveyor belt.

[0015] By adopting the above solution, the material tray sorting method of the present invention achieves fully automated operation of the entire process from material tray connection, sorting, weighing, appearance inspection to qualified product conveying and defective product rejection through the coordinated cooperation of the material tray sorting equipment's connection mechanism, sorting mechanism, transfer mechanism, defective product channel, roller conveyor line, lifting mechanism, unloading channel and control system. In the entire sorting process, the connection robot of the connection mechanism, the sorting robot and weighing module of the sorting mechanism, the transfer robot of the transfer mechanism, the defective product channel, roller conveyor line, lifting mechanism, unloading channel and each camera and sensor are all uniformly coordinated and controlled by the control system, realizing continuous and automated operation of each step, replacing manual sorting, greatly improving sorting efficiency, reducing labor costs, and avoiding the problem of high error rate caused by manual operation. Attached Figure Description

[0016] Figure 1 This is an exploded view of the material tray sorting device of the present invention.

[0017] Figure 2 This is a schematic diagram of the combination of the material tray sorting equipment of the present invention.

[0018] Figure 3 This is a top view schematic diagram of the material tray sorting equipment of the present invention.

[0019] Figure 4 This is a schematic diagram of the connection mechanism of the present invention.

[0020] Figure 5 This is a schematic diagram of the docking robot arm of the present invention.

[0021] Figure 6 This is a schematic diagram of the sorting table of the present invention.

[0022] Figure 7 This is a schematic diagram of the sorting robot of the present invention.

[0023] Figure 8 This is a schematic diagram of the transplanting robot of the present invention.

[0024] Figure 9 This is a schematic diagram of the structure of the double-layer roller of the present invention.

[0025] Figure 10 This is a schematic diagram of the lifting platform of the present invention.

[0026] Label Explanation: 1. Connecting Mechanism; 11. Connecting Platform; 111. Installation Area; 112. Connecting Roller; 12. Connecting Robotic Arm; 121. Mounting Base; 122. First Robotic Arm; 123. Second Robotic Arm; 124. Robotic Gripper; 125. First Joint; 126. Second Joint; 127. Third Joint; 128. Gripper; 129. Clamping Plate; 13. Sensor; 14. First Camera; 2. Sorting Mechanism; 21. Sorting Platform; 211. Sorting Roller; 212. Walking Trough; 213. Weighing Area; 22. Sorting Robotic Arm; 221. Sorting X-axis Guide Rail; 222. Sorting Y-axis Guide Rail; 223. Sorting Z-axis Guide Rail; 224. Sorting Gripper; 225. First Rotary Cylinder; 226. Second Rotary Cylinder; 227. Gripper Fixing Seat; 228. Material Tray Clamping Plate; 23. Weighing Module; 24. Second camera; 3. Transplanting mechanism; 31. Transplanting frame; 32. Transplanting robot; 321. Transplanting X-axis guide rail; 322. Transplanting Y-axis guide rail; 323. Transplanting Z-axis guide rail; 324. Transplanting suction cup; 325. Suction cup mounting base; 326. Suction cup; 33. Third camera; 4. Defective product channel; 41. Defective product conveyor belt; 42. Defective product conveyor bracket; 43. Defective product drive mechanism; 5. Roller conveyor line; 51. Roller bracket; 52. Upper roller line; 53. Lower roller line; 6. Lifting mechanism; 61. Lifting column; 62. Lifting base; 63. Lifting plate; 64. Lifting guide rail; 65. Lifting slide; 66. Lifting motor; 67. Roller; 7. Unloading channel; 8. Material box; 81. Opening; 82. Partition; 9. Material tray; 10. Pallet. Detailed Implementation

[0027] To further explain the technical solution of the present invention, the present invention will be described in detail below through specific embodiments.

[0028] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0029] like Figures 1 to 10 As shown, the present invention discloses a material tray sorting device, which includes a connecting mechanism 1, a sorting mechanism 2, a transfer mechanism 3, a defective product channel 4, a roller conveyor line 5, a lifting mechanism 6, and a material unloading channel 7.

[0030] The connecting mechanism 1 includes a connecting platform 11 and a connecting robot 12. An installation area 111 is located in the middle of the connecting platform 11, and the connecting robot 12 is installed within the installation area 111. Multiple connecting rollers 112 are installed on both sides of the connecting platform 11. One end of the connecting platform 11 connects to an AGV (Automated Guided Vehicle) trolley, and the other end connects to the sorting platform 21 of the sorting mechanism 2. The connecting rollers 112 on both sides move in opposite directions. One connecting roller 112 is used to transport a box 8 loaded with a tray 9. The box 8 loaded with the tray 9 can be transported to the connecting roller 112 by the AGV trolley, and the box 8 is transported to one end of the sorting platform 21 by the rolling of the connecting roller 112. The other connecting roller 112 is used to transport empty boxes 8 from the sorting platform 21, and the empty boxes 8 are transported to an AGV trolley (not shown in the figure) via the connecting roller 112, and then transported by the AGV trolley to the tray loading area for reuse.

[0031] One side of the material box 8 is an opening 81. Inside the material box 8, on both sides corresponding to the opening 81, there are multiple corresponding partitions 82. Each partition 82 can hold one material tray 9, and one material box 8 can hold multiple material trays 9. The material trays 9 are taken out and put in through the opening 81 of the material box 8. Preferably, one end of the material tray 9 can protrude outside the material box 8 for easier handling.

[0032] The docking robot 12 includes a mounting base 121, a first robotic arm 122, a second robotic arm 123, and a robotic gripper 124. The mounting base 121 and the first robotic arm 122 are connected by a first joint 125, allowing the first robotic arm 122 to rotate 360° relative to the mounting base 121. The second robotic arm 123 is connected to the first robotic arm 122 by a second joint 126, allowing the second robotic arm 123 to rotate 360° relative to the first robotic arm 122. The second robotic arm 123 and the robotic gripper 124 are connected by a third joint 127, allowing the robotic gripper 124 to rotate 360° relative to the second robotic arm 123. The robotic gripper 124 includes a clamping claw 128 and two spaced-apart clamping plates 129, with the clamping claw 128 and clamping plates 129 arranged perpendicularly. The mechanical claw 124 is provided with a sensor 13 on one side of the gripper 128. The mechanical claw 124 is provided with a first camera 14 at the position between the two clamping plates 129 to determine the position of the material tray 9 in the material box 8 so that the two clamping plates 129 can accurately grip the material tray 9.

[0033] The sorting mechanism 2 includes a sorting platform 21, a sorting robot 22, and a weighing module 23. The sorting platform 21 is connected to one end of the connecting platform 11. The two sides of the sorting platform 21 are provided with two sorting rollers 211 corresponding to the two connecting rollers 112 of the connecting platform 11. The center of the sorting platform 21 is provided with a traveling groove 212 arranged along the movement direction of the sorting rollers. The sorting robot 22 includes a sorting X-axis guide rail 221, a sorting Y-axis guide rail 222, a sorting Z-axis guide rail 223, and sorting grippers 224. The sorting X-axis guide rail 221 is fixedly installed in the travel groove 212. The sorting Z-axis guide rail 223 is slidably mounted on the sorting X-axis guide rail 221. The sorting Y-axis guide rail 222 is slidably mounted on the sorting Z-axis guide rail 223. The sorting grippers 224 are slidably mounted on the sorting Y-axis guide rail 222. The slide connecting the sorting grippers 224 to the sorting Y-axis guide rail 222 has a horizontally rotating mechanism. The first rotary cylinder 225 rotates, and a second rotary cylinder 226 is fixedly mounted on the first rotary cylinder 225. The sorting gripper 224 has a gripper fixing seat 227 and two material tray clamping plates 228. The second rotary cylinder 226 is connected to the rear end of the gripper fixing seat 227. A second camera 24 is installed at the front end of the gripper fixing seat 227. Two material tray clamping plates 228 are installed at intervals on one side of the gripper fixing seat 227. After the position of the material tray 9 is obtained by the second camera 24, the two material tray clamping plates 228 of the sorting gripper 224 clamp the material tray 9.

[0034] The sorting platform 21 has a weighing area 213 extending forward at the front center. The walking groove 212 extends to the weighing area 213. The weighing module 23 is installed on the weighing area 213. The sorting gripper 224 of the sorting robot 22 picks up the material tray 9 and places it on the weighing module 23 for weighing.

[0035] The transplanting mechanism 3 includes a transplanting frame 31 and a transplanting robot 32. The weighing area 213 of the sorting platform 21 is inserted into the transplanting frame 31 from the rear end. The transplanting robot 32 is installed at the top of the transplanting frame 31 and includes a transplanting X-axis guide rail 321, a transplanting Y-axis guide rail 322, a transplanting Z-axis guide rail 323, and a transplanting suction cup 324. The transplanting X-axis guide rail 321 is spaced apart on the left and right sides of the top of the transplanting frame 31. The transplanting Y-axis guide rail 322 is slidably mounted on the transplanting X-axis guide rail 321. The transplanting Z-axis guide rail 323 is slidably mounted on the transplanting X-axis guide rail 321. 23 is slidably mounted on the transplanting Y-axis guide rail 322, and the transplanting suction cup 324 is slidably mounted on the transplanting Z-axis guide rail 323. In this embodiment, the transplanting suction cup 324 includes a suction cup fixing seat 325 and two sets of suction cups 326. One end of the suction cup fixing seat 325 is slidably mounted on the transplanting Z-axis guide rail 323, and the two sets of suction cups 326 are spaced apart at both ends of the suction cup fixing seat 325. A third camera 33 is provided between the two sets of suction cups 326 on the suction cup fixing seat 325. The third camera 33 is used to acquire the weighed material tray 9 and determine whether the appearance of the material tray 9 meets the requirements.

[0036] The defective product channel 4 includes a defective product conveyor belt 41, a defective product conveying bracket 42, and a defective product driving mechanism 43. One end of the defective product conveying bracket 42 is located inside the transplanting frame 31 in front of the weighing module 23, and the other end protrudes to the outside of one side of the transplanting frame 31. The defective product conveyor belt 41 is mounted on the defective product conveying bracket 42, and the conveying direction is from inside the transplanting frame 31 to outside the transplanting frame 31. The defective product driving mechanism 43 is located on the defective product conveying bracket 42 below the defective product conveyor belt 41. The defective product driving mechanism 43 is connected to the defective product conveyor belt 41 and is used to drive the defective product conveyor belt 41 to move on the defective product conveying bracket 42.

[0037] The roller conveyor line 5 is correspondingly set in the transplanting frame 31 at the square end of the defective product conveying bracket 42. The roller conveyor line 5 has a roller bracket 51, an upper roller line 52, and a lower roller line 53. The roller bracket 51 is installed in the transplanting frame 31. The upper roller line 52 and the lower roller line 53 are arranged vertically on the roller bracket 51. The lifting mechanism 6 is installed at the front end and the rear end of the roller conveyor line 5, respectively.

[0038] The lifting mechanism 6 includes a lifting column 61, a lifting base 62, a lifting plate 63, a lifting guide rail 64, a lifting slide 65, and a lifting motor 66. The lifting column 61 is located on one side of the transplanting frame 31. The lifting base 62 is located at the bottom end of the lifting column 61 facing the transplanting frame 31. The lifting guide rail 64 is fixedly located at both ends of the lifting column 61 facing the transplanting frame 31. The lifting slide 65 is slidably mounted on the lifting guide rail 64. One end of the lifting plate 63 is fixed to the lifting slide 65, and the other end faces the transplanting frame 31. The lifting plate 63 is provided with multiple rollers 67. The push plate of the lifting motor 66 is connected to the lifting slide 65, controlling the lifting slide 65 to move up and down on the lifting guide rail 64.

[0039] The feeding channel 7 is located on one side of the lifting mechanism at the rear end of the transplanting frame 31. The feeding channel 7 and the adjacent lifting mechanism 6 can be connected by a robotic arm (not shown in the figure) or by setting up a manual position to realize the transfer of the material tray.

[0040] The connecting robot 12 of the connecting mechanism 1, the sorting robot 22 and weighing module 23 of the sorting mechanism 2, the transplanting robot 32 of the transplanting mechanism 3, the defective product channel 4, the roller conveyor line 5, the lifting motor 66 of the lifting mechanism 6, the unloading channel 7, the first camera 14, the second camera 24 and the third camera 33 are respectively connected to the control system.

[0041] The lower roller conveyor 53 of the roller conveyor 5 is used to transport empty pallets 10 from front to back, and lifts them to the upper roller conveyor 52 by the lifting plate 63 of the lifting mechanism 6, so that the empty pallets 10 can be loaded with weighed and inspected trays 9, and the inspected trays 9 can be transferred to the upper roller conveyor 52 or the defective product channel 4 by the transfer robot 32.

[0042] The working principle of the material tray sorting equipment of this invention is based on the coordinated operation of various mechanisms. Through unified control by the control system, the automated sorting of material trays is achieved. The material tray sorting method specifically includes the following steps: S1. The AGV trolley transports the material box 8 loaded with the material tray 9 to the transfer platform 11 of the transfer mechanism 1. The transfer roller on one side of the transfer platform 11 transfers the material box 8 towards the sorting mechanism 2. At the same time, the first camera 14 and sensor 13 on the transfer robot 12 cooperate to obtain the position and presence information of the material tray 9 in the material box 8. The transfer robot 12 picks up the material box 8 or the material tray 9 according to the information and transfers it to the sorting platform 21 of the sorting mechanism 2. The connecting rollers on both sides of the connecting platform 11 move in opposite directions. One connecting roller transmits the material box 8 loaded with the material tray 9, while the other connecting roller transmits the empty material box 8, thus realizing bidirectional synchronous transmission of the material box 8.

[0043] The first camera 14 captures images of the distribution of material trays 9 inside the material box 8 in real time and transmits them to the control system. The control system analyzes the stacking state of the material trays 9 through an image recognition algorithm. If the stacking of material trays is detected to be tilted or misaligned, the control system controls the multi-joint joints of the connecting robot arm 12 to adjust the posture in coordination. The robot arm gently corrects the position of the material trays 9 through the gripper of the mechanical claw before clamping, so as to avoid damage to the material trays 9 during the clamping process.

[0044] S2. Sorting and transfer: The sorting rollers of the sorting platform 21 work with the connecting rollers of the connecting platform 11 to achieve stable transfer of the material box. The second camera 24 on the sorting robot 22 obtains the position information of the material tray 9 on the sorting platform 21. The sorting robot 22 adjusts its position through the multi-axis guide rail and adjusts its angle through the rotary cylinder to accurately grip the material tray 9 and transfer it to the weighing module 23 at the front end of the sorting platform 21. S3. Weighing detection: The weighing module 23 weighs the material tray and transmits the weight data to the control system. The control system determines whether the weight of the material tray 9 meets the preset standard. Before each weighing, the control system controls the sorting robot to transfer a standard weight to the weighing module for calibration. After calibration, the weight is reset and the material tray is weighed again to ensure the long-term accuracy of the weighing data.

[0045] S4. Appearance inspection: The third camera on the transplanting robot arm acquires an image of the appearance of the weighed material tray and transmits the image information to the control system. The control system analyzes the appearance image and determines whether the appearance of the material tray meets the preset requirements. S5. Sorting and diversion: The control system judges whether the material tray is qualified based on the weight detection result and the appearance inspection result. If the material tray is unqualified, the transfer robot will transfer it to the defective product channel, and the defective product channel will transport the defective material tray to the outside of the equipment. If the material tray is qualified, the transfer robot will transfer it to the empty tray of the upper roller line of the roller conveyor. S6. Pallet replenishment: The lower roller conveyor of the roller conveyor transports empty pallets in reverse. When the upper roller conveyor needs an empty pallet, the lifting mechanism lifts the empty pallet from the lower roller conveyor to the upper roller conveyor, thus completing the empty pallet replenishment. S7. Unloading and output: The pallet loaded with qualified material trays is transferred to the rear lifting mechanism through the upper roller conveyor. The pallet is then transferred to the unloading channel by a robotic arm or manual station, completing the final output of the qualified material trays. S8. Empty box recycling: After all the material trays in the box have been transferred, the sorting rollers of the sorting platform will transfer the empty box to the connecting rollers on the other side of the connecting platform. The connecting rollers on this side will transfer the empty box to the AGV trolley, and the AGV trolley will transport the empty box to the material tray loading area for reuse.

[0046] The control system records the sorting time, weighing data, appearance inspection results, and sorting path information of each material tray in real time, and generates a traceable sorting log. The log data is uploaded to the factory management system in real time for production scheduling and quality traceability.

[0047] The above embodiments and figures are not intended to limit the product form and style of the present invention. Any appropriate changes or modifications made by those skilled in the art should be considered as not departing from the patent scope of the present invention.

Claims

1. A tray sorting method, characterized by: Based on the realization of tray sorting equipment, the tray sorting equipment comprises a docking mechanism, a sorting mechanism, a transplanting mechanism, a defective product channel, a roller transmission line, a lifting mechanism, a discharging channel and a control system; The docking mechanism comprises a docking platform and a docking manipulator, the docking manipulator is installed on the docking platform, the rear end of the docking platform is connected with the AGV car, the front end of the docking platform is connected with the sorting platform of the sorting mechanism, the docking manipulator is used to realize the transplanting of the tray between the AGV car, the docking platform and the sorting platform, the first camera and the sensor are arranged on the docking manipulator; The sorting mechanism comprises a sorting platform, a sorting manipulator and a weighing module; the sorting platform is connected with the front end of the docking platform, the sorting manipulator is installed on the sorting platform, the second camera is arranged on the sorting manipulator, and the weighing module is arranged at the front end of the sorting platform and within the stroke range of the sorting manipulator; The transplanting mechanism comprises a transplanting frame and a transplanting manipulator, the transplanting manipulator is installed at the top end of the transplanting frame, the weighing module, one end of the defective product channel and one end of the roller transmission line are respectively within the stroke range of the transplanting manipulator, the third camera is arranged on the transplanting manipulator, and the third camera is used to obtain the tray after weighing and judge whether the appearance of the tray meets the requirements; The roller transmission line is correspondingly arranged in the transplanting frame, the roller transmission line comprises a roller support, an upper roller line and a lower roller line, the upper roller line and the lower roller line are arranged on the roller support in a spaced manner, the lifting mechanism is arranged at the front end and the rear end of the roller transmission line, the upper roller line is used to transmit the tray loaded with qualified trays, the lower roller line is used to reversely transmit the empty tray, and the lifting mechanisms at the front end and the rear end of the roller transmission line are used to transplant the empty tray in the lower layer to the upper roller line; The discharging channel is connected with the lifting mechanism at the rear end of the transplanting frame, the discharging channel and the adjacent lifting mechanism are connected through a mechanical arm or an artificial station to realize the transplanting of the qualified tray, and the empty tray is transplanted to the lower roller line through the lifting mechanism; The docking manipulator of the docking mechanism, the sorting manipulator of the sorting mechanism, the weighing module, the transplanting manipulator of the transplanting mechanism, the defective product channel, the roller transmission line, the lifting mechanism, the discharging channel and the third camera are connected with the control system; The tray sorting method comprises the following steps: S1, docking transmission, the AGV car transports the tray-loaded tray box to the docking platform of the docking mechanism, the docking roller on one side of the docking platform transmits the tray box to the sorting mechanism, the first camera and the sensor on the docking manipulator cooperate to obtain the position and existence information of the tray in the tray box, and the docking manipulator clamps and transplants the tray box or the tray to the sorting platform of the sorting mechanism according to the information; S2, sorting transfer, the sorting roller of the sorting platform cooperates with the docking roller of the docking platform to realize stable transmission of the tray box, the second camera on the sorting manipulator obtains the position information of the tray on the sorting platform, the sorting manipulator adjusts the position through the multi-axis guide rail and adjusts the angle through the rotary cylinder, accurately clamps and transfers the tray to the weighing module at the front end of the sorting platform; S3, weight detection, the weighing module weighs the tray, and transmits the weight data to the control system, and the control system judges whether the tray weight meets the preset standard; S4, appearance detection, the third camera on the transplanting manipulator acquires the appearance image of the weighed tray, and transmits the image information to the control system, and the control system analyzes the appearance image to judge whether the appearance of the tray meets the preset requirement; S5, sorting and distribution, the control system comprehensively judges whether the tray is qualified according to the weight detection result and the appearance detection result: if the tray is unqualified, the transplanting manipulator transfers it to the defective product channel, and the defective product channel transports the defective tray to the outside of the equipment; if the tray is qualified, the transplanting manipulator transfers it to the empty tray of the upper layer of the roller transmission line; S6, tray supply, the lower layer of the roller transmission line reversely transmits the empty tray, when the upper layer of the roller transmission line needs the empty tray, the lifting mechanism lifts the empty tray of the lower layer of the roller transmission line to the upper layer of the roller transmission line, and the empty tray supply is completed; S7, output of the unloaded tray, the tray loaded with the qualified tray is transmitted to the rear end lifting mechanism through the upper layer of the roller transmission line, and the tray is transferred to the unloading channel through the mechanical arm or the manual position, and the final output of the qualified tray is completed; S8, empty box recycling, when all the trays in the box are transferred, the sorting roller of the sorting platform transmits the empty box to the connection roller on the other side of the connection platform, the connection roller on the side transmits the empty box to the AGV trolley, and the AGV trolley transports the empty box to the tray loading area for reuse.

2. A tray sorting method as claimed in claim 1, characterized in that: In step S1, the movement directions of the connection rollers on the two sides of the connection platform are opposite, one side of the connection roller transmits the tray-loaded box, and the other side of the connection roller transmits the empty box, realizing bidirectional synchronous transmission of the box.

3. A tray sorting method as claimed in claim 1, characterized in that: In step S1, the first camera shoots the tray distribution image in the box in real time and transmits it to the control system, the control system analyzes the stacking state of the tray through the image recognition algorithm, if the tray stacking is detected to be inclined or misaligned, the multi-joint of the connection manipulator is controlled to adjust the posture, and the tray position is gently corrected through the clamping plate of the mechanical claw before clamping.

4. A tray sorting method as claimed in claim 1, characterized in that: In step S3, before each weighing, the control system controls the sorting manipulator to transfer a standard weight counterweight to the weighing module for calibration, and after calibration, the counterweight is reset, and then the tray is weighed, to ensure the long-term accuracy of the weighing data.

5. A tray sorting method as claimed in claim 2, characterized in that: The control system records the sorting time, weighing data, appearance detection result and sorting path information of each tray in real time, and generates a traceable sorting log, and the log data is uploaded to the factory management system in real time, for production scheduling and quality traceability.

6. A tray sorting method as claimed in claim 1, characterized in that: The control system presets the weight qualified range of the tray, when the weight of the tray is within the qualified range, it is determined to be weight qualified; when the weight of the tray exceeds the qualified range, it is directly determined to be an unqualified tray, without subsequent appearance detection, and the transplanting manipulator directly transfers it to the defective product channel.

7. A tray sorting method as claimed in claim 1, characterized in that: The conveying direction of the defective product channel is from inside to outside of the transplanting frame, the transplanting manipulator places the defective tray on the defective product conveying belt, and the defective product driving mechanism drives the conveying belt to quickly transport the defective tray to the outside of the equipment, to avoid mixing with the qualified products.

8. A tray sorting method as claimed in claim 1, characterized in that: Two sides of the sorting platform are provided with sorting rollers corresponding to the connection rollers of the connection platform, the center of the sorting platform is provided with a walking groove arranged along the movement direction of the sorting rollers, the walking groove extends to a weighing area at the front end of the sorting platform, a weighing module is installed on the weighing area, and the sorting manipulator directly transfers the tray to the weighing module along the walking groove without transfer.

9. A tray sorting method as claimed in claim 1, characterized in that: The connection manipulator comprises a mounting base, a first mechanical arm, a second mechanical arm and a mechanical claw, the mounting base and the first mechanical arm are connected through a first joint, the second mechanical arm and the first mechanical arm are connected through a second joint, and the second mechanical arm and the mechanical claw are connected through a third joint; the first joint, the second joint and the third joint can all rotate by 360 degrees; the mechanical claw comprises a clamping claw and two clamping plates arranged at intervals, the clamping claw and the clamping plates are arranged perpendicularly, the mechanical claw is provided with a sensor on one side of the clamping claw, and the mechanical claw is provided with a first camera at a position corresponding to the space between the two clamping plates.

10. A tray sorting apparatus as claimed in claim 1, characterized in that: The defective product channel comprises a defective product conveying belt, a defective product conveying support and a defective product driving mechanism, one end of the defective product conveying support is arranged in the transplanting frame in front of the weighing module, the other end protrudes to the outside of one side of the transplanting frame, the defective product conveying belt is installed on the defective product conveying support, the conveying direction is from the inside of the transplanting frame to the outside of the transplanting frame, the defective product driving mechanism is arranged on the defective product conveying support below the defective product conveying belt, and the defective product driving mechanism is connected with the defective product conveying belt.

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