Full-automatic ton bag unpacking machine

Abstract

The invention discloses a full-automatic ton bag unpacking machine. Comprising a rack, a sliding rail arranged on the upper portion of the rack, an electric hoist moving along the sliding rail, a bag hanging assembly connected with the electric hoist and a temporary storage hopper assembly arranged in the middle of the rack. The sealing bin assembly is located below the temporary storage hopper assembly and can ascend and descend relative to the temporary storage hopper assembly; the bag opening assembly is arranged on the sealing bin assembly and integrally extends into a sealing bin for operation; the slide rail is used for limiting the motion path of the electric hoist; the bag hanging assembly is used for fixing bag lugs of the ton bag, so that the ton bag is kept in a stable posture in the lifting and moving process; the buffer hopper assembly is used for receiving materials discharged from the ton bags; the sealing bin assembly is in sealing connection with the buffering hopper assembly in the unpacking and discharging process and used for constructing a relatively-closed operation space to restrain dust from escaping. According to the unpacking device, the synergistic effect of automation, sealing and high efficiency is achieved, and dust pollution and manual labor intensity are reduced while the unpacking efficiency is improved.

Description

Technical Field

[0001] This invention belongs to the technical field of ton bag unpacking machines, specifically relating to a fully automatic ton bag unpacking machine. Background Technology

[0002] Ton bag unpacking machines are widely used in industries such as chemical, pharmaceutical, and food processing, primarily for unpacking and processing bulk materials. However, existing ton bag unpacking machines still suffer from insufficient automation and rely heavily on manual labor. During the unpacking process, workers must manually open the ton bag opening, cut the inner bag, and unload the material. This not only significantly reduces operational efficiency and keeps labor intensity consistently high, but also directly increases occupational health risks for workers. Especially in high-dust, high-intensity working environments, frequent manual operations can easily lead to respiratory illnesses and occupational injuries. Furthermore, because it is difficult to achieve a completely sealed process during unpacking and unloading, dust inevitably escapes into the work area, compromising the cleanliness of the working environment and potentially contaminating subsequent production processes, causing quality and safety hazards. More importantly, existing equipment has limited adaptability to different material types. For powdery materials with poor flowability or prone to caking, its processing efficiency drops significantly, further limiting the widespread application of the equipment across multiple industries and working conditions. In addition to the key issues mentioned above, existing ton bag unpacking machines also have some minor but not insignificant shortcomings. First, in the inner bag opening cutting stage, due to the lack of stable automated positioning and precise control, manual intervention is often required for adjustment, which can easily lead to cutting deviations and even require repeated operations. This not only prolongs the operation time but may also cause uneven damage to the inner bag, increasing the risk of secondary contamination. Second, at the unloading end stage, residual material is often difficult to completely discharge, especially when the material has a certain degree of viscosity or an arching effect, which can easily form a stagnant layer in the hopper. Such residues not only reduce material utilization and cause raw material waste but also have an adverse effect on the continuity and stability of subsequent production processes. Summary of the Invention

[0003] The main objective of this invention is to overcome the shortcomings and deficiencies of the prior art and propose a fully automatic ton bag unpacking machine, which achieves the synergistic effect of automation, airtightness and high efficiency, and effectively reduces dust pollution and manual labor intensity while improving unpacking efficiency.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A fully automatic ton bag unpacking machine includes a frame, a slide rail set on the upper part of the frame, an electric hoist that moves along the slide rail, a bag hanging assembly connected to the electric hoist, a buffer hopper assembly set in the middle of the frame, a sealing chamber assembly located below the buffer hopper assembly and capable of being raised and lowered relative to it, and a bag opening assembly set on the sealing chamber assembly and extending into the interior of the sealing chamber for operation.

[0006] The frame is used to carry and support the various functional components, and the slide rail is used to limit the movement path of the electric hoist, thereby realizing the lifting and positioning of the ton bag;

[0007] The bag hanging assembly is used to secure the bag handles of the ton bag, so that the ton bag maintains a stable posture during lifting and moving, so that subsequent unpacking operations can be carried out smoothly;

[0008] The buffer hopper assembly is used to receive material discharged from the ton bag;

[0009] The sealed bin assembly forms a sealed connection with the buffer hopper assembly during unpacking and unloading, creating a relatively enclosed working space to suppress dust escape; the sealed bin assembly is equipped with an output valve to control material discharge;

[0010] The bag opening assembly includes a cutting component and a vision component. The cutting component acts as an actuator to perform physical cutting actions. The vision component acts as a sensing mechanism, integrating a hardware module with image acquisition and processing functions. It is installed below the cutting component to collect image data of the bottom of the ton bag in real time, locate the center of the bag opening through algorithms, and feed the coordinates back to the control system to drive the cutting blade. The two work together to enable the cutting operation to be completed automatically in a closed environment, improving operational safety and environmental friendliness.

[0011] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0012] 1. This invention introduces an intelligent vision cutting system into the cutting assembly, enabling automatic identification, positioning, and cutting of the inner bag opening of the ton bag. This eliminates the need for manual searching and cutting. The cutter, guided by vision, completes insertion, clamping, and cutting, and then quickly withdraws after completion. The entire process requires no manual intervention, significantly reducing the labor intensity of workers, ensuring the accuracy and consistency of bag opening operations, and improving unpacking efficiency. Compared with traditional manual operation, this intelligent vision cutting system combines target detection, semantic segmentation, and depth perception technologies to achieve millimeter-level positioning accuracy and high cutting success rate in complex environments. It also shortens cutting time and avoids inner bag damage and secondary contamination caused by miscutting.

[0013] 2. In the unloading process, the present invention adopts the method of moving the sealed chamber upward to form a reliable closed environment. The automatic opening and closing of the chamber door further reduces the dust leakage path, so that cutting and unloading are carried out in a closed state, thereby effectively reducing dust escape, improving workshop air quality and reducing the harm to workers' health.

[0014] 3. Through the adaptive linkage mechanism, the present invention can automatically adjust the connection between the electric hoist and the ton bag according to the change in the weight of the remaining material in the ton bag. When it is determined that the material has been discharged, the system can quickly detach the electric hoist from the ton bag and complete the automatic recycling of the empty bag, avoiding secondary dust and safety hazards caused by human intervention.

[0015] 4. The linkage between the inner bag opening traction mechanism and the cutting blade assembly ensures that the bag opening is stabilized before cutting, effectively preventing accidental cutting and secondary cutting, and further improving the safety and reliability of the system. Attached Figure Description

[0016] Figure 1 This is an overall architecture diagram of an embodiment of the present invention.

[0017] Figure 2 This is a schematic diagram of the cutter assembly in the embodiment.

[0018] Figure 3 This is a schematic diagram of the bag hanging assembly in the embodiment.

[0019] Figure 4 This is a schematic diagram of the sealing chamber assembly in the embodiment.

[0020] Figure 5 This is a schematic diagram of the buffer hopper assembly in the embodiment.

[0021] Figure 6 This is a schematic diagram of the workflow of the intelligent vision cutting system in the embodiment.

[0022] Reference numerals: 1-Frame; 2-Slide rail; 3-Electric hoist; 4-Bag hanging assembly; 5-Buffer hopper assembly; 6-Sealed chamber assembly; 7-Bag opening assembly; 8-Cutter body; 9-Vision sensor; 10-Cutter transfer mechanism; 11-Output valve; 12-Cutter assembly; 13-Vision assembly; 14-Buffer hopper; 15-Vibration motor; 16-Air spring. Detailed Implementation

[0023] The present invention will be further described in detail below with reference to the embodiments and accompanying drawings, but the embodiments of the present invention are not limited thereto.

[0024] Examples; such as Figure 1 , Figure 2 , Figure 3 , Figure 4 as well as Figure 5 As shown, a fully automatic ton bag unpacking machine includes a frame 1, a slide rail 2, an electric hoist 3, a bag hanging assembly 4, a buffer hopper assembly 5, a sealing chamber assembly 6, and a bag opening assembly 7.

[0025] In this embodiment, the fully automatic ton bag unpacking machine uses an RHS (cold-formed square hollow steel) frame as its basic load-bearing structure. The overall structure is stable and reliable, capable of withstanding the long-term operation requirements of large-tonnage materials, thus avoiding safety hazards caused by frame deformation. Figures 1 to 5 As shown, the overall device includes a frame, a slide rail on the upper part of the frame, an electric hoist that moves along the slide rail, a bag hanging assembly connected to the electric hoist, a buffer hopper assembly in the middle of the frame, a sealing chamber assembly located below the buffer hopper assembly and capable of being raised and lowered relative to it, and a bag opening assembly that extends from the sealing chamber assembly to the inside of the sealing chamber for operation.

[0026] The frame is used to carry and support the various functional components, and the slide rail is used to limit the movement path of the electric hoist, thereby realizing the lifting and positioning of the ton bag;

[0027] The bag-hanging assembly is used to secure the bag handles of the ton bag, ensuring that the bag maintains a stable posture during lifting and movement, so that subsequent unpacking operations can proceed smoothly. Compared with the traditional method of relying on manual handling, this design not only significantly reduces the labor intensity of workers, but also improves the efficiency and safety of bag hanging and positioning, thus mitigating occupational health risks caused by frequent manual operations from the source.

[0028] The buffer hopper assembly is used to receive material discharged from the ton bag;

[0029] The sealed chamber assembly forms a sealed connection with the buffer hopper assembly during unpacking and unloading, which is used to create a relatively closed working space to suppress dust escape; the sealed chamber assembly is equipped with an output valve 11 to control material discharge.

[0030] The bag opening assembly includes a cutter assembly 12 and a vision assembly 13. The cutter assembly acts as an actuator to perform physical cutting actions. The vision assembly acts as a sensing mechanism, integrating a hardware module with image acquisition and processing functions. It is installed below the cutter assembly to acquire image data of the bottom of the ton bag in real time, locate the center of the bag opening through algorithms, and feed the coordinates back to the control system to drive the cutter. The two work together to enable the cutting operation to be completed automatically in a closed environment, improving operational safety and environmental friendliness.

[0031] like Figure 1 and Figure 5 As shown, the buffer hopper assembly specifically includes a buffer hopper 14, a vibration motor 15 mounted on the buffer hopper, and an air spring 16 mounted below or inside the buffer hopper.

[0032] The air spring provides elastic support to the ton bag during unloading, preventing it from sagging and affecting material flow. The vibrating motor breaks up material bridging and adhesion by applying vibration, ensuring continuous and uniform material drop and reducing residue. This combination significantly reduces unloading residue and material retention, improves material utilization, and ensures the continuity of subsequent processes.

[0033] like Figure 1 and Figure 4 As shown, the buffer hopper works in conjunction with the sealing chamber assembly below it to form a flexible sealing interface through a soft rubber sealing device, so that the entire cutting and unloading process is completed in a basically sealed state, thereby significantly reducing dust leakage. Compared with the traditional open unloading method, this design effectively improves the cleanliness of the work area, reduces the risk of workers inhaling dust, and helps to meet the stringent environmental regulations.

[0034] like Figure 4 As shown, the front of the sealed chamber assembly is equipped with an automatically opening and closing operating chamber door, which provides an entry channel for the cutting assembly while avoiding dust leakage paths caused by manual opening and closing.

[0035] like Figure 2 As shown, in this embodiment, the cutter assembly 12 specifically includes a cutter body 8 and a cutter transfer mechanism 10, and the vision assembly is specifically a vision sensor 9. The cutter transfer mechanism serves as a motion carrier and is fixedly installed outside the sealed chamber assembly. The cutter body is located at the moving end of the cutter transfer mechanism and is driven by it to perform alignment, cutting, and cutting actions. The vision sensor is located below the fixed bracket of the cutter transfer mechanism and is located outside the movement path of the cutter body. The vision sensor is used to collect images of the bag opening inside the ton bag and perform identification and positioning. The cutter transfer mechanism drives the cutter body to complete the alignment, cutting, and retraction actions of the bag opening based on the identification results, so as to realize the automatic opening of the inner bag opening.

[0036] In this embodiment, the cutter body is a rotary double-edged cutting head; the cutter assembly also includes a high-precision linear module, which drives the rotary double-edged cutting head for cutting; the rotary double-edged cutting head has a built-in six-dimensional force sensor for real-time monitoring of cutting resistance.

[0037] The cutting assembly is equipped with an intelligent vision cutting system. This system combines the YOLOv10 object detection algorithm with the U-Net semantic segmentation network. Specifically, YOLOv10 first performs rapid detection and classification of the bag opening, the contents of the packaging bag, and the hanging bag, outputting a coarse localization area of ​​the bag opening. Then, within this area, U-Net performs pixel-level semantic segmentation, extracting the bag opening edge and center line. Combined with depth sensor data, three-dimensional coordinate calculations are performed to finally obtain the center line coordinates of the bag opening and the optimal cutting path. In this embodiment, the intelligent vision cutting system further introduces a Generative Adversarial Network (GAN) to enhance the image, thereby improving image quality in low-light or dynamic scenes and ensuring the stability and reliability of the visual recognition process.

[0038] The workflow of the intelligent vision cutting system is as follows: Figure 6 As shown, the intelligent vision cutting system first acquires images of the bag opening using an industrial camera, and then enhances the images using a GAN model. Subsequently, YOLOv10 is used to detect and locate the bag opening region. Within the region of interest, U-Net semantic segmentation and TOF depth information are combined to calculate the 3D position of the bag opening and the cutting path. Based on this, the intelligent vision cutting system guides the cutter to complete rapid approach, precise positioning, and adaptive cutting, and achieves closed-loop control and anomaly protection through force feedback and safety monitoring. Specifically, this intelligent vision cutting system uses a 2-megapixel industrial camera (frame rate ≥30fps) with a ring LED fill light for image acquisition, supplemented by a TOF-based depth sensor for multi-source information fusion target detection.

[0039] In this embodiment, the intelligent vision cutting system employs three-level motion control:

[0040] During the rapid approach phase, the cutting mechanism is moved to a position 10mm above the bag opening at a speed of 500mm / s.

[0041] Fine-tuning is achieved through visual servo control during the precise positioning phase;

[0042] During the adaptive cutting phase, the cutting parameters are adjusted in real time based on the force feedback signal, and an obstacle avoidance strategy is triggered when a sudden change in resistance is detected, thereby improving the safety and stability of the cutting process.

[0043] In this embodiment, the intelligent visual cutting system also combines convolutional neural networks (CNN) and reinforcement learning (RL), enabling the system to not only accurately extract image features and identify targets, but also continuously optimize control strategies based on real-time feedback of cutting results. In addition, by learning from historical data and the real-time environment, the intelligent visual cutting system gradually improves the cutting performance, achieving adaptive adjustment and continuous optimization in dynamic environments, thereby further improving the efficiency and accuracy of cutting.

[0044] In this embodiment, to ensure operational safety, the intelligent vision cutting system has constructed a dual hardware and software protection mechanism, including an electronic fence to monitor the distance between the blade and the bag in real time, and an emergency braking mechanism that completes emergency stop and retraction within 50ms when the cutting resistance exceeds 30N.

[0045] The intelligent visual cutting system in this embodiment combines YOLOv10 target detection with U-Net semantic segmentation, and introduces GAN enhancement, CNN feature extraction and RL optimization strategies to form a system with multi-sensor fusion, force feedback adaptive control and full-process closed-loop adjustment. It not only avoids the cutting deviation and secondary contamination problems in traditional manual operation, but also significantly improves the automation level and reliability of the unpacking process, and has broad application prospects and outstanding practical value.

[0046] In this embodiment, an adaptive linkage mechanism is also included, which is used to automatically adjust the connection status according to the changes in the material inside the bag during the unloading process. When it is determined that the material has been discharged, the ton bag can be automatically separated from the lifting device to realize the empty bag recycling and reduce manual operation and dust risk.

[0047] The adaptive linkage mechanism adds a weighing sensor to the unloading hopper. Based on the attitude feedback caused by the change in the weight of the remaining material in the ton bag, it automatically adjusts the connection status and force relationship between the ton bag and the electric hoist. When the system determines that the material has been discharged, it controls the electric hoist to detach from the ton bag, realizing the recycling of the empty bag and avoiding secondary dust and operational risks caused by human intervention.

[0048] In this embodiment, an inner bag opening traction mechanism is also included, which can automatically open and fix the bag opening after the ton bag is installed in place, so that it is aligned with the center of the hopper, expands the opening, improves the material falling flow effect, and prevents the bag opening from shrinking back.

[0049] The cutter assembly is linked with the inner bag opening traction mechanism: the cutter remains in a retracted state during the traction action, and the cutter unfolds to perform the cutting after the traction mechanism has completed clamping and stabilizing.

[0050] In this embodiment of the fully automatic ton bag unpacking machine, during operation, the worker hangs the bag ears of the ton bag on the electric hoist using the bag hanging assembly, and the machine then completes the lifting and positioning of the ton bag. After the outer bag opening is opened, the ton bag is smoothly sent to the top of the buffer hopper, and the sealing chamber automatically moves up and contacts and presses against the hopper. Subsequently, the intelligent vision cutting system is activated to identify the inner bag opening, and the cutting assembly completes the cutting under guidance. After the cutting is completed, the operating chamber door is immediately closed and the unloading stage begins. During the unloading process, the air spring and the vibration motor work together to effectively solve the problems of material residue and poor flowability, ensuring thorough unloading and reducing material waste.

[0051] It should also be noted that, in this specification, terms such as "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0052] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A fully automatic ton bag unpacking machine, characterized in that, It includes a frame, a slide rail on the upper part of the frame, an electric hoist that moves along the slide rail, a bag hanging assembly connected to the electric hoist, a buffer hopper assembly in the middle of the frame, a sealing chamber assembly located below the buffer hopper assembly and capable of being raised and lowered relative to it, and a bag opening assembly that is set on the sealing chamber assembly and extends into the interior of the sealing chamber for operation. The frame is used to carry and support the various functional components, and the slide rail is used to limit the movement path of the electric hoist, thereby realizing the lifting and positioning of the ton bag; The bag hanging assembly is used to secure the bag handles of the ton bag, so that the ton bag maintains a stable posture during lifting and moving, so that subsequent unpacking operations can be carried out smoothly; The buffer hopper assembly is used to receive material discharged from the ton bag; The sealed bin assembly forms a sealed connection with the buffer hopper assembly during unpacking and unloading, creating a relatively enclosed working space to suppress dust escape; the sealed bin assembly is equipped with an output valve to control material discharge; The bag opening assembly includes a cutting assembly and a vision assembly. The cutting assembly acts as an actuator to perform physical cutting actions. The vision assembly acts as a sensing mechanism, integrating a hardware module with image acquisition and processing functions. It is installed below the cutting assembly to collect image data of the bottom of the ton bag in real time, locate the center of the bag opening through algorithms, and feed the coordinates back to the control system to drive the cutting assembly. The collaboration between the two enables the cutting operation to be completed automatically in a closed environment, improving operational safety and environmental friendliness.

2. The fully automatic ton bag unpacking machine according to claim 1, characterized in that, The buffer hopper assembly specifically includes a buffer hopper, a vibrating motor mounted on the buffer hopper, and an air spring mounted below or inside the buffer hopper; Among them, the air spring is used to provide elastic support for the ton bag during the unloading process to prevent the bag from sagging and affecting the material flow; the vibration motor applies vibration to break up material arching and adhesion, thereby ensuring that the material falls continuously and evenly and reducing residue.

3. The fully automatic ton bag unpacking machine according to claim 1, characterized in that, The cutting assembly specifically includes a cutting body and a cutting transfer mechanism, while the vision assembly is a vision sensor. The cutting transfer mechanism, as a moving carrier, is fixedly installed outside the sealed compartment assembly. The cutting body is located at the moving end of the cutting transfer mechanism and is driven by it to perform alignment, cutting, and cutting actions. The vision sensor is located below the fixed bracket of the cutting transfer mechanism and outside the movement path of the cutting body. The vision sensor is used to acquire images of the bag opening inside the ton bag and perform identification and positioning. Based on the identification results, the cutting transfer mechanism drives the cutting body to complete the alignment, cutting, and retraction actions of the bag opening, thereby realizing the automatic opening of the inner bag opening.

4. The fully automatic ton bag unpacking machine according to claim 3, characterized in that, The cutter body is a rotary double-edged cutting head; The cutting assembly also includes a high-precision linear module that drives a rotary double-edged cutting head for cutting; the rotary double-edged cutting head has a built-in six-dimensional force sensor for real-time monitoring of cutting resistance.

5. The fully automatic ton bag unpacking machine according to claim 3, characterized in that, The cutting assembly is equipped with an intelligent vision cutting system; The intelligent vision cutting system uses an industrial camera with a ring LED fill light for image acquisition, and is supplemented by a TOF principle depth sensor to perform multi-source information fusion for target detection. In the visual recognition part, the intelligent visual cutting system combines the YOLOv10 target detection algorithm with the U-Net semantic segmentation network. YOLOv10 first detects and classifies the bag opening, the contents of the packaging bag and the hanging bag, and outputs the coarse localization area of ​​the bag opening. Then, U-Net is used in this area to complete pixel-level semantic segmentation, extract the edge and center line of the bag opening, and combine the depth sensor data to calculate the three-dimensional coordinates, and finally obtain the center line coordinates of the bag opening and the optimal cutting path. The intelligent visual segmentation system also introduces a generative adversarial network (GAN) to enhance images, thereby improving image quality in low-light or dynamic scenes and ensuring the stability and reliability of the visual recognition process.

6. The fully automatic ton bag unpacking machine according to claim 5, characterized in that, The intelligent vision cutting system adopts three-level motion control: During the rapid approach phase, the cutting mechanism is moved to a position 10mm above the bag opening at a speed of 500mm / s. Fine-tuning is achieved through visual servo control during the precise positioning phase; During the adaptive cutting phase, the cutting parameters are adjusted in real time based on the force feedback signal, and an obstacle avoidance strategy is triggered when a sudden change in resistance is detected, thereby improving the safety and stability of the cutting process.

7. The fully automatic ton bag unpacking machine according to claim 5, characterized in that, The intelligent visual cutting system also combines convolutional neural networks (CNN) and reinforcement learning (RL), enabling the system to not only accurately extract image features and identify targets, but also to continuously optimize control strategies based on real-time feedback of the cutting effect. By learning from historical data and real-time environments, the intelligent vision cutting system gradually improves the cutting performance, achieving adaptive adjustment and continuous optimization in dynamic environments, thereby further improving cutting efficiency and accuracy.

8. The fully automatic ton bag unpacking machine according to claim 5, characterized in that, The intelligent vision cutting system also features a dual hardware and software protection mechanism, including an electronic fence for real-time monitoring of the distance between the blade and the bag, and an emergency braking system that completes emergency stop and retraction within 50ms when the cutting resistance exceeds 30N.

9. The fully automatic ton bag unpacking machine according to claim 1, characterized in that, It also includes an adaptive linkage mechanism, which automatically adjusts the connection status according to the changes in the material inside the bag during the unloading process. When it is determined that the material has been discharged, it can automatically separate the ton bag from the lifting device to realize the empty bag recycling and reduce manual operation and dust risk. The adaptive linkage mechanism adds a weighing sensor to the unloading hopper. Based on the attitude feedback caused by the change in the weight of the remaining material in the ton bag, it automatically adjusts the connection status and force relationship between the ton bag and the electric hoist. When the system determines that the material has been discharged, it controls the electric hoist to detach from the ton bag, realizing the recycling of the empty bag and avoiding secondary dust and operational risks caused by human intervention.

10. A fully automatic ton bag unpacking machine according to claim 1, characterized in that, It also includes an inner bag opening traction mechanism, which can automatically open and fix the bag opening after the ton bag is installed in place, so that it is aligned with the center of the hopper, expands the opening, improves the material falling flow effect and prevents the bag opening from shrinking back. The cutter assembly is linked with the inner bag opening traction mechanism: the cutter remains in a retracted state during the traction action, and the cutter unfolds to perform the cutting after the traction mechanism has completed clamping and stabilizing.

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