Self-circulation method for charging basket in combined drawing process

Abstract

The invention discloses a self-circulation method for a charging basket in a combined drawing process, and aims to solve the problems of low efficiency, high labor intensity, shortage of crane resources and the like due to the fact that an existing combined drawing process depends on a crane to hoist and transport the charging basket. The device mainly comprises a first roller way, a chain roller way, a lifting roller way, a transition roller way, a lifting rotating roller way, a lifting weighing roller way, a platform scale, a discharging way and the like. The working process comprises the steps that empty material baskets are conveyed to a material receiving tray after being transferred, steered and positioned through a plurality of roller ways, full material baskets are conveyed and automatically weighed after being wound and then conveyed to a pre-storage area through a discharging way, and all the mechanisms are cyclically reset to achieve self-circulation of the material baskets. According to the method, empty material baskets and full material baskets can be pre-stored, weighing is automatically completed, the driving time is greatly saved, the production efficiency is improved, the labor intensity is reduced, and the production continuity is guaranteed.

Description

Technical Field

[0001] This invention belongs to the technical field of copper tube drawing process, and particularly relates to a self-circulating method for the material basket in the drawing process. Background Technology

[0002] In the continuous drawing process of copper tube production, with the continuous expansion of production capacity, the transfer and circulation of material baskets has become a key link affecting production efficiency. In the existing technology, the continuous drawing process needs to complete a large number of copper tube winding operations per shift. The corresponding material baskets need to be hoisted by an overhead crane. The specific process is as follows: place empty material baskets in the work area, hoist full material baskets away from the work position, and weigh full material baskets using the crane's built-in weighing scale. After the operator records the weight data, the full material baskets are then transferred to the designated storage area.

[0003] This operating method has several technical drawbacks: First, the overhead crane's single lifting and weighing operations are time-consuming, leading to excessive time occupation over time. Each shift alone requires a significant amount of man-hours for lifting the material baskets, severely consuming crane resources. Second, the overhead crane often faces situations where multiple processes are used simultaneously, and there is an unforeseen risk of downtime due to equipment failure. If the overhead crane cannot operate normally, the delivery and retrieval of material baskets will be forced to stop, directly causing the connecting equipment to stop waiting for materials, seriously affecting production continuity. Third, with the continuous increase in equipment density in the production workshop, the operating space of the overhead crane is limited, and the demand for its use is becoming increasingly tight, further exacerbating the bottleneck problem of material basket transfer. Fourth, empty material baskets need to be stored centrally on the ground, and when needed, they must be lifted again by the overhead crane to the connecting process, making the transfer process cumbersome. Furthermore, full material baskets lack an orderly pre-storage mechanism, easily leading to problems such as messy stacking and inconvenient retrieval. At the same time, there are many manual interventions, which not only increases the labor intensity of operators but also easily affects production efficiency and material management accuracy due to human error. Therefore, there is an urgent need for a self-circulating method that can realize automatic transfer, pre-storage, and weighing of material baskets, in order to solve the technical problems of existing technologies such as reliance on overhead cranes for transportation, low production efficiency, poor operation continuity, and high labor intensity. Summary of the Invention

[0004] The purpose of this invention is to provide a self-circulating method for the material basket in the connecting process, so as to solve the problems mentioned in the background art.

[0005] In view of this, the present invention provides a method for self-circulation of material baskets in a continuous pulling process, comprising the following steps: S1: Empty material basket supply preparation, the externally hoisted empty material basket is transported to the first roller conveyor 1, the first roller conveyor 1 performs initial positioning of the empty material basket to ensure that the empty material basket is arranged along the preset conveying direction; S2: Empty material basket primary transfer, the first roller conveyor 1 transfers the empty material basket to the chain roller conveyor 2, the chain roller conveyor 2 is connected to the first roller conveyor 1 at a preset angle, and the smooth transition and continuous conveying of the empty material basket is achieved through chain drive; S3: Empty material basket lifting and reversing pre-processing, chain roller conveyor 2 conveys the empty material basket to lifting roller conveyor 3, lifting roller conveyor 3 adjusts the height of the empty material basket through lifting action, so that the conveying surface of the empty material basket is at the same level as the conveying surface of the subsequent transition roller conveyor 4. S4: Empty material basket is turned and conveyed. The lifting roller conveyor 3 lowers the empty material basket to the transition roller conveyor 4. After the transition roller conveyor 4 drives the empty material basket to complete the direction change, the empty material basket is transferred to the first lifting and rotating roller conveyor 5. S5: Empty material basket positioning and supply. The first lifting and rotating roller conveyor 5 adjusts to a horizontal state that matches the second roller conveyor 7 by synchronously executing lifting and rotating actions. Then, the empty material basket is transferred to the receiving tray 8 to complete the automatic supply of empty material baskets. The first lifting and rotating roller conveyor 5 rises and rotates back to the initial position to receive the next empty material basket. S6: Full basket output trigger. After the connecting process completes the winding operation to form a full basket, the full basket is transferred to the second lifting and rotating roller conveyor 9. S7: Full basket primary transfer, the second lifting and rotating roller conveyor 9 adjusts to a horizontal state that matches the third roller conveyor 10 by synchronously executing lifting and rotating actions, and transfers the full basket to the third roller conveyor 10. S8: Weighing and transferring the full material basket. The third roller conveyor 10 transfers the full material basket to the lifting weighing roller conveyor 11. The lifting weighing roller conveyor 11 drives the full material basket to descend, so that the full material basket is completely placed in the weighing area of ​​the platform scale 12, and the automatic weighing of the full material basket is completed. S9: Full material basket discharge conveyor. After weighing is completed, the lifting weighing roller 11 drives the full material basket to rise and reset, and transfers the full material basket to the discharge channel 13. The discharge channel 13 conveys the full material basket to the preset storage area. S10: Mechanism reset cycle, the second lifting rotating roller 9 and the lifting weighing roller 11 are reset to their initial state, waiting for the transfer of the next full material basket. At the same time, the first roller 1 continues to receive empty material baskets hoisted from the outside. Repeat steps S1 to S9 to realize the self-circulation of the material basket in the connecting process.

[0006] In a further embodiment of the present invention, in step S1, before the first roller conveyor 1 receives the empty material basket, the external dimensions of the empty material basket are tested for compatibility. Only empty material baskets whose external dimensions meet the preset standards are allowed to enter the first roller conveyor 1. The first roller conveyor 1 limits and guides the empty material basket through adjustable side baffles to ensure that the empty material basket is conveyed along the preset center line.

[0007] In a further embodiment of the present invention, in step S4, before the transition roller 4 drives the empty material basket to turn, it first detects the real-time status of the first lifting and rotating roller 5. The turning action is only started when the first lifting and rotating roller 5 is idle and reset to the preset receiving posture. During the turning process, the offset of the empty material basket is corrected in real time to ensure that the empty material basket accurately enters the first lifting and rotating roller 5.

[0008] In a further embodiment of the present invention, in step S5, after the first lifting and rotating roller conveyor 5 transfers the empty material basket to the receiving tray 8, it confirms whether the empty material basket is completely in place by a distance detection element. If it is not completely in place, the first lifting and rotating roller conveyor 5 performs a replenishment action, pushing the empty material basket to the preset working position of the receiving tray 8. After the replenishment is completed, the first lifting and rotating roller conveyor 5 resets.

[0009] In a further embodiment of the present invention, in step S6, before the full basket is transferred to the second lifting and rotating roller conveyor 9, the material coverage detection element detects the coverage range of the material in the basket. Only after confirming that the material coverage range has reached the preset full material standard is the transfer action to the second lifting and rotating roller conveyor 9 initiated. Furthermore, a flexible pushing method is adopted during the transfer process to avoid impacting the material in the basket.

[0010] In a further embodiment of the present invention, in step S8, when the platform scale 12 weighs the full material basket, the lifting weighing roller 11 is kept stationary. After the weighing data stabilizes for a preset time, the weight data is locked and recorded. At the same time, the weight data is synchronized to the associated storage unit. After the weighing is completed, a unique corresponding weight identifier is generated and bound to the material basket.

[0011] In a further embodiment of the present invention, in step S9, when the discharge channel 13 is conveying a full material basket, the stacking height of the material baskets in the pre-storage area is detected in real time. When the stacking height of the material baskets in the pre-storage area reaches a preset threshold, the discharge channel 13 automatically adjusts the conveying direction and conveys the full material basket to the backup pre-storage area. The full material baskets are arranged in an orderly manner in a stacked manner in the pre-storage area.

[0012] In a further embodiment of the present invention, between steps S3 and S4, an empty material basket bearing surface flatness detection step is added. The bearing surface of the empty material basket is detected by a flatness detection element. If the flatness of the bearing surface exceeds the preset allowable range, the empty material basket is diverted to the abnormal material basket storage area to avoid affecting the subsequent material loading quality.

[0013] In a further embodiment of the present invention, the conveying resistance data of each roller is collected in real time during all conveying steps, and the driving force of the roller is dynamically adjusted according to the conveying resistance data. When the conveying resistance exceeds the preset safety range, the conveying action of the corresponding roller is stopped immediately and a warning signal is issued. The conveying is restarted after the resistance returns to normal.

[0014] In a further embodiment of the present invention, a process coordination and linkage step is also included, which collects production rhythm data of the connecting process in real time, and dynamically adjusts the conveying speed of each roller, the operating frequency of the lifting mechanism and the allocation strategy of the pre-stored area according to the production rhythm data, so that the self-circulation speed of the material basket matches the production rhythm of the connecting process, and realizes the coordinated and efficient operation of the whole process.

[0015] The beneficial effects of this invention are: 1. Achieve fully automated circulation of material baskets, significantly improving production efficiency: Through the coordinated operation of multiple mechanisms such as the first roller conveyor 1, chain roller conveyor 2, and lifting and rotating roller conveyor, a complete self-circulating system is constructed, which automatically supplies empty material baskets, automatically transfers full material baskets, weighs them, and pre-stores them. This eliminates the need for frequent lifting and weighing of material baskets by overhead cranes, significantly reducing the time spent by overhead cranes and avoiding production interruptions caused by overlapping use or malfunctions of overhead cranes. This saves a significant amount of ineffective working hours per shift, effectively improving the continuous operation capability of the connecting process and thus increasing output per unit time.

[0016] 2. Optimize the storage and circulation of material baskets and reduce management costs: It can realize the automatic pre-storage and orderly supply of a preset number of empty material baskets, while full material baskets can be pre-stored in an orderly manner through the discharge channel 13. This solves the problem of empty material baskets being piled up on the ground and full material baskets being placed haphazardly in traditional technology, reduces the risk of collision damage during the material basket transfer process, improves the utilization rate of workshop space and the standardization of material management, and reduces the management costs of manual sorting and scheduling.

[0017] 3. Improve operational accuracy and product quality stability: By setting up compatibility tests, flatness tests, and position corrections at each key step, we ensure that empty material baskets meet usage standards and are placed accurately, avoiding the impact of incorrect basket size, uneven bearing surface, or placement misalignment on material loading quality. During the weighing process of full material baskets, a data stability locking and identification binding mechanism is adopted to ensure accurate and traceable weight data, providing a reliable basis for adjusting production parameters, thereby improving the stability of product quality.

[0018] 4. Low labor intensity and operational risks: The entire process of transferring, positioning, and weighing the material baskets requires no manual intervention, which greatly reduces the labor intensity of crane operators and related personnel, while avoiding potential safety hazards that may occur during manual intervention; through mechanisms such as conveying resistance monitoring and abnormal early warning, abnormal equipment operation can be detected and handled in a timely manner, ensuring the safety and reliability of the material basket transfer process.

[0019] 5. Collaborative and linked processes to adapt to dynamic capacity adjustment: Through collaborative and linked processes, the self-circulation parameters of the material basket can be dynamically adjusted according to the production rhythm of the linked processes, so that the speed of material basket supply, transfer and pre-storage matches the production capacity. This avoids equipment waiting for materials due to insufficient supply of empty material baskets, and also prevents the space occupation caused by the accumulation of full material baskets. It improves the synergy and flexibility of the entire production process and can adapt to the production needs under different capacity scales. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the present invention. Detailed Implementation

[0021] The technical solutions of the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application are within the scope of protection of this application.

[0022] In the description of this application, it should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. For ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it need not be further discussed in subsequent drawings.

[0023] It should be noted that the terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects and not to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that embodiments of this application can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class, without limiting the number of objects; for example, the first object can be one or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0024] It should be noted that in the description of this application, the directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description. Unless otherwise stated, these directional terms 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 on the scope of protection of this application. The directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0025] It should be noted that, in this application, the terms "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 limitations, 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 that element. Furthermore, it should be noted that the scope of the methods and apparatuses in the embodiments of this application is not limited to performing functions in the order shown or discussed, but may also include performing functions substantially simultaneously or in the reverse order, depending on the functions involved. For example, the described methods may be performed in a different order than described, and various steps may be added, omitted, or combined. Additionally, features described with reference to certain examples may be combined in other examples.

[0026] This embodiment provides a method for self-circulating material baskets in a continuous pulling process, including the following steps: S1: Empty material basket supply preparation. At the feeding end of the copper tube drawing process, empty material baskets that are hoisted to the designated feeding area by a crane are transported one by one to the first roller conveyor 1. The first roller conveyor 1 is adapted to the size and specifications of the material baskets used for copper tube production. The empty material baskets are initially positioned by the anti-slip conveying structure on the surface of the roller conveyor. At the same time, the guide components on both sides of the roller conveyor limit the conveying trajectory of the empty material baskets, ensuring that the empty material baskets are accurately arranged along the preset conveying direction. This lays the foundation for the subsequent connection and conveying with the chain roller conveyor 2, and avoids the impact of the flow efficiency due to the placement of the empty material baskets. This step does not require manual positioning, reduces manual intervention, and improves the automation level of empty material basket supply.

[0027] S2: Empty material basket primary transfer. The first roller conveyor 1 smoothly transfers the empty material basket to the chain roller conveyor 2 through the synchronous rotation of the rollers. The chain roller conveyor 2 is connected to the first roller conveyor 1 at a preset angle (adapting to the workshop layout and subsequent process connection requirements). The chain roller conveyor 2 adopts a combination structure of wear-resistant chain and load-bearing plate, which is adapted to the load-bearing requirements of the material basket in copper tube production. Through the continuous transmission of the chain, the empty material basket is smoothly transitioned and continuously transported from the first roller conveyor 1 to the lifting roller conveyor 3, avoiding jamming or tilting of the empty material basket during the transfer process. Compared with traditional manual transfer or single roller conveyor, it significantly improves the stability and continuity of empty material basket transfer, providing a guarantee for the efficient operation of subsequent processes.

[0028] S3: Empty material basket lifting and reversing pre-processing. The chain roller conveyor 2 continuously transports the empty material basket to the carrying area of ​​the lifting roller conveyor 3. The lifting roller conveyor 3 has a built-in powerful lifting drive component, which is adapted to the weight requirements of the material basket in the copper tube connecting process. Through precise lifting and lowering actions, the height of the empty material basket is adjusted so that the conveying surface of the empty material basket is strictly at the same level as the conveying surface of the subsequent transition roller conveyor 4, eliminating the height difference between different roller conveyors. This ensures that the empty material basket is free from bumps and jams during the reversing process, achieving a smooth transition. This step solves the risk of material basket damage or material spillage caused by inconsistent heights in traditional transfer, while also improving the efficiency of reversing pre-processing.

[0029] S4: Empty material basket turning and conveying. The lifting roller conveyor 3 slowly lowers the empty material basket onto the bearing surface of the transition roller conveyor 4. The transition roller conveyor 4 adopts a rotatable conveying structure. According to the layout requirements of the copper tube connecting process, it drives the empty material basket to complete the direction change of the preset angle, ensuring that the conveying direction of the empty material basket is completely matched with the receiving direction of the first lifting rotating roller conveyor 5. Then, the empty material basket is accurately transferred to the first lifting rotating roller conveyor 5. The turning process is smooth and efficient, avoiding the interruption of conveying due to directional deviation, ensuring the continuity of the empty material basket flow, and thus improving the production efficiency of the entire connecting process.

[0030] S5: Empty material basket positioning and supply. The first lifting and rotating roller conveyor 5 has a built-in lifting and rotating mechanism with coordinated control. By synchronously executing the lifting and rotating actions, it is precisely adjusted to a horizontal state that matches the second roller conveyor 7, ensuring that the two are connected without deviation. Then, the empty material basket is smoothly transferred to the receiving tray 8 through the transmission of the roller conveyor. The receiving tray 8 is the direct feeding station for the copper tube pulling and winding operation, completing the automatic supply of empty material baskets and meeting the continuous winding requirements of the pulling process. After that, the first lifting and rotating roller conveyor 5 quickly rises and rotates back to the initial position, and promptly connects to the next empty material basket, realizing the continuous supply of empty material baskets. This step realizes the precise positioning of the empty material basket from the flow to the working position, eliminating the need for manual placement, reducing labor intensity, and ensuring the continuity of the winding operation.

[0031] S6: Full basket output trigger. After the winding equipment of the connecting process completes the copper tube winding operation, a full basket containing copper tubes is formed. The full basket is smoothly transferred to the receiving area of ​​the second lifting and rotating roller conveyor 9 by the material push component of the winding equipment. This process does not require immediate hoisting by the crane, avoiding the time loss of waiting for the crane in traditional operations, ensuring that the full basket can leave the working position in time, freeing up space for the next round of winding operations, and improving the turnover rate of the connecting process.

[0032] S7: The full basket is transferred in the first stage. The second lifting and rotating roller conveyor 9 also performs lifting and rotating actions synchronously to accurately adjust to a horizontal state that matches the third roller conveyor 10, eliminating the connection height difference and directional deviation. Then, the full basket is smoothly transferred to the third roller conveyor 10. The structural strength of the second lifting and rotating roller conveyor 9 is adapted to the load-bearing requirements of the full basket (which is relatively heavy after loading copper pipes), ensuring a safe and stable transfer process, avoiding tilting of the full basket or damage to the copper pipes, and realizing the rapid transfer of the full basket, saving time for the subsequent weighing process.

[0033] S8: Weighing and transferring the full material basket. The third roller conveyor 10 continuously transfers the full material basket to the lifting weighing roller conveyor 11. The lifting weighing roller conveyor 11 drives the full material basket to descend slowly, so that the full material basket is completely placed in the weighing area of ​​the platform scale 12, and the center of gravity of the full material basket coincides with the weighing center of the platform scale 12, ensuring accurate weighing data and completing the automatic weighing of the full material basket. Compared with the traditional overhead crane weighing, this step does not require manual assistance for alignment, the weighing efficiency is higher, the data is more accurate, and the safety hazards caused by the shaking of the full material basket during the weighing process are avoided, providing reliable data support for quality traceability and capacity statistics of copper tube production.

[0034] S9: Full basket discharge conveyor. After weighing, the lifting weighing roller conveyor 11 drives the full basket to rise and reset. The full basket is transferred to the discharge channel 13 through roller conveyor transmission. The discharge channel 13 transports the full basket to the preset storage area according to the preset path, realizing the automatic pre-storage of the full basket. There is no need for manual handling and stacking. This step realizes the automated flow of the full basket from weighing to storage, avoids the problem of messy stacking in the traditional way, improves the site utilization rate, and facilitates subsequent centralized hoisting and reduces the frequent operation of the crane.

[0035] S10: Mechanism reset cycle. The second lifting and rotating roller conveyor 9 and the lifting and weighing roller conveyor 11 are quickly reset to their initial state, waiting for the transfer of the next full material basket in time, ensuring the continuity of the cycle process. At the same time, the first roller conveyor 1 continuously receives empty material baskets hoisted from the outside. Repeat steps S1 to S9 to realize the self-circulation of the material basket in the connecting process. The entire cycle process does not require the use of a crane for frequent transfer and auxiliary operation of the material basket, which greatly saves the crane running time, improves the production efficiency of the connecting process, and ensures the continuity of production.

[0036] In this embodiment, in step S1, before the first roller conveyor 1 receives the empty material basket, the size detection component set at the entrance of the roller conveyor performs a compatibility test on the outer dimensions of the empty material basket. Only empty material baskets whose outer dimensions meet the preset standards for copper tube production are allowed to enter the first roller conveyor 1. This avoids subsequent flow jams or incompatibility with the receiving tray 8 due to the size of the material basket not matching. In addition, the first roller conveyor 1 limits and guides the empty material basket through adjustable side baffles. The spacing of the side baffles can be adjusted according to different specifications of empty material baskets to ensure that the empty material basket is always conveyed along the preset center line, improving the versatility and accuracy of the flow, further ensuring the smooth connection of subsequent processes, and reducing the equipment downtime adjustment time caused by the deviation of the material basket.

[0037] In this embodiment, in step S4, before the transition roller conveyor 4 drives the empty material basket to turn, the status detection component detects the real-time status of the first lifting and rotating roller conveyor 5 in real time, including whether it is in an idle state and whether it has been reset to a preset receiving posture. The turning action is only started when the first lifting and rotating roller conveyor 5 meets the receiving conditions to avoid material basket congestion or docking deviation. During the turning process, the displacement detection component monitors the position of the empty material basket in real time and corrects the offset of the empty material basket in real time according to the detection data to ensure that the empty material basket accurately enters the first lifting and rotating roller conveyor 5, improves the connection success rate, reduces process interruption caused by docking errors, and ensures the high efficiency of material basket circulation.

[0038] In this embodiment, in step S5, after the first lifting and rotating roller conveyor 5 transfers the empty material basket to the receiving tray 8, the distance detection element set around the receiving tray 8 detects the distance between the empty material basket and the preset working position of the tray to confirm whether the empty material basket is completely in place. If it is not completely in place, the first lifting and rotating roller conveyor 5 starts the replenishment action, pushing the empty material basket to the preset working position of the receiving tray 8 through the small transmission of the roller conveyor, ensuring that the empty material basket is accurately connected to the output end of the winding equipment, and avoiding deviation or spillage of the copper tube during the winding process due to the deviation of the empty material basket. After the replenishment is completed, the first lifting and rotating roller conveyor 5 is reset to ensure the quality and stability of the winding operation.

[0039] In this embodiment, in step S6, before the full basket is transferred to the second lifting and rotating roller conveyor 9, the material coverage detection element installed above the receiving tray 8 detects the coverage range of the copper tubes in the basket. Only after confirming that the copper tube coverage range reaches the preset full material standard (no obvious gaps, and the loading amount meets the production capacity requirements) is the transfer action to the second lifting and rotating roller conveyor 9 initiated. This avoids the waste of circulating resources caused by the unfilled basket entering the subsequent process. In addition, a flexible pushing method is adopted during the transfer process. A buffer pad is set at the contact part between the pushing component and the full basket to avoid impact on the copper tubes in the basket, prevent the copper tubes from being deformed or scratched, and ensure the quality of the copper tube products.

[0040] In this embodiment, in step S8, when the platform scale 12 weighs the full material basket, the lifting weighing roller 11 stops its transmission and remains stationary to avoid the vibration generated by the roller operation affecting the accuracy of the weighing data. After the weighing data stabilizes for a preset time (to ensure the data is true and reliable), the weight data is locked and recorded by the data processing module. At the same time, the weight data is synchronized to the associated production management storage unit to realize the real-time storage and traceability of the weight data. After the weighing is completed, a unique corresponding weight identifier (associated with the material basket number and production batch) is generated and bound to the material basket to facilitate subsequent product quality traceability and capacity statistics, providing accurate data support for production management and improving the management refinement level of copper tube production.

[0041] In this embodiment, in step S9, when the discharge channel 13 is conveying a full basket, the height of the basket stacking is detected in real time by a height detection element set in the pre-storage area. When the height of the basket stacking in the pre-storage area reaches a preset threshold (to avoid the risk of collapse due to excessive stacking), the discharge channel 13 automatically adjusts the conveying direction through the steering component to convey the full basket to the backup pre-storage area. The full baskets are arranged in an orderly stacked manner in the pre-storage area, with each layer of baskets neatly arranged and evenly spaced. This not only improves the space utilization of the pre-storage area but also facilitates centralized hoisting by the crane, avoiding the hoisting difficulties and basket damage caused by traditional messy stacking, while ensuring the safety of the pre-storage process.

[0042] In this embodiment, between steps S3 and S4, an empty material basket bearing surface flatness detection step is added. The bearing surface of the empty material basket is fully inspected by a flatness detection element (such as a laser flatness detector). If the flatness of the bearing surface exceeds the preset allowable range, it indicates that the empty material basket may be deformed, which cannot guarantee the stability of the copper tube winding process. At this time, the empty material basket is diverted to the abnormal material basket storage area by the diversion component to avoid the copper tube winding deviation, deformation or surface damage caused by the uneven bearing surface of the material basket, thus ensuring the quality of subsequent material loading and improving the qualification rate of copper tube products.

[0043] In this embodiment, each roller conveyor is equipped with a resistance detection component in all conveying steps to collect resistance data in real time during the conveying process. The driving force of the roller conveyor is dynamically adjusted according to the resistance data. When the weight of the material basket is large or there is slight friction on the surface of the roller conveyor, the driving force is automatically increased to ensure smooth conveying. When the conveying resistance exceeds the preset safety range (which may be caused by foreign objects blocking or material basket displacement), the conveying action of the corresponding roller conveyor is stopped immediately, and a warning signal is issued through the audible and visual alarm component to remind the staff to troubleshoot the fault in time. The conveying is restarted after the resistance returns to normal to avoid damage to the roller conveyor or tipping of the material basket due to overload, and to ensure the safe operation of the equipment and the integrity of the material basket and copper pipe.

[0044] This embodiment also includes a process coordination and linkage step. The production rhythm data of the connecting process is collected in real time through the data acquisition module, including winding speed, single winding time, and unit time capacity. Based on this data, the conveying speed of each roller conveyor, the operation frequency of the lifting mechanism, and the allocation strategy of the pre-storage area are dynamically adjusted. When the capacity of the connecting process increases, the conveying speed of the roller conveyor and the operation frequency of the lifting mechanism are accelerated to ensure timely supply of empty baskets and rapid transfer of full baskets. When a certain area of ​​the pre-storage area is about to be full, the allocation strategy is adjusted in advance to guide the full basket to the empty area, so that the self-circulation speed of the basket is precisely matched with the production rhythm of the connecting process, realizing the coordinated and efficient operation of the entire process, maximizing the overall production efficiency of the connecting process, and avoiding resource waste.

[0045] Through the coordinated design of roller drive, chain drive, and lifting and rotating roller conveyor, a high-level technical effect of "micro-stress control and energy efficiency self-optimization throughout the copper tube production process" was unexpectedly achieved while realizing the self-circulation of the material basket. On the one hand, the starting and stopping impact and high-altitude swaying of the material basket during traditional overhead crane transportation can cause hidden residual stress in the copper tube billet. However, the smooth transition of each roller conveyor and the synchronous buffering action of the lifting and rotating mechanism in this method control the acceleration of the material basket within a small range throughout the entire circulation process (from empty basket supply to full basket storage). The copper tube billet always remains relatively stationary in the material basket, reducing the amount of residual stress generated. The cracking rate of the tube in the subsequent deep processing stage is significantly reduced, indirectly improving the mechanical properties and dimensional accuracy stability of the finished tube. This effect breaks through the conventional view that "material basket transportation only solves the efficiency problem". This method achieves deep coupling between the transfer process and product performance. On the other hand, the coordinated action and load adaptability design of each mechanism in the method automatically reduces the roller driving force during the empty basket transfer stage to 30% of that during the full basket transfer stage. Furthermore, the lifting and rotating rollers automatically switch to a low-power mode in standby mode. Combined with the dynamic speed adjustment strategy of process coordination, the energy consumption per unit capacity of the entire method is reduced compared to the traditional mode. At the same time, because the material basket transfer is smooth and without downtime, the effective running time of the connecting equipment is increased, forming a positive cycle of "energy efficiency self-optimization - equipment stability improvement - capacity premium". This effect exceeds the expected goal of simply "saving driving time", and achieves a multi-dimensional coordinated upgrade of production efficiency, product quality and energy consumption control, providing a new technical path for the green and high-precision transformation of copper tube production.

[0046] The embodiments of this application have been described above with reference to the accompanying drawings. Unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other. This application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of this application without departing from the spirit and scope of the claims, and all of these forms are within the protection scope of this application.

Claims

1. A method of self-circulation of a draw process basket, characterized by, Includes the following steps: S1: Empty material basket supply preparation, the externally hoisted empty material basket is transported to the first roller conveyor 1, the first roller conveyor 1 performs initial positioning of the empty material basket to ensure that the empty material basket is arranged along the preset conveying direction; S2: Empty material basket primary transfer, the first roller conveyor 1 transfers the empty material basket to the chain roller conveyor 2, the chain roller conveyor 2 is connected to the first roller conveyor 1 at a preset angle, and the smooth transition and continuous conveying of the empty material basket is achieved through chain drive; S3: Empty material basket lifting and reversing pre-processing, chain roller conveyor 2 conveys the empty material basket to lifting roller conveyor 3, lifting roller conveyor 3 adjusts the height of the empty material basket through lifting action, so that the conveying surface of the empty material basket is at the same level as the conveying surface of the subsequent transition roller conveyor 4. S4: Empty material basket is turned and conveyed. The lifting roller conveyor 3 lowers the empty material basket to the transition roller conveyor 4. After the transition roller conveyor 4 drives the empty material basket to complete the direction change, the empty material basket is transferred to the first lifting and rotating roller conveyor 5. S5: Empty material basket positioning and supply. The first lifting and rotating roller conveyor 5 adjusts to a horizontal state that matches the second roller conveyor 7 by synchronously executing lifting and rotating actions. Then, the empty material basket is transferred to the receiving tray 8 to complete the automatic supply of empty material baskets. The first lifting and rotating roller conveyor 5 rises and rotates back to the initial position to receive the next empty material basket. S6: Full basket output trigger. After the connecting process completes the winding operation to form a full basket, the full basket is transferred to the second lifting and rotating roller conveyor 9. S7: Full basket primary transfer, the second lifting and rotating roller conveyor 9 adjusts to a horizontal state that matches the third roller conveyor 10 by synchronously executing lifting and rotating actions, and transfers the full basket to the third roller conveyor 10. S8: Weighing and transferring the full material basket. The third roller conveyor 10 transfers the full material basket to the lifting weighing roller conveyor 11. The lifting weighing roller conveyor 11 drives the full material basket to descend, so that the full material basket is completely placed in the weighing area of ​​the platform scale 12, and the automatic weighing of the full material basket is completed. S9: Full material basket discharge conveyor. After weighing is completed, the lifting weighing roller 11 drives the full material basket to rise and reset, and transfers the full material basket to the discharge channel 13. The discharge channel 13 conveys the full material basket to the preset storage area. S10: Mechanism reset cycle, the second lifting rotating roller 9 and the lifting weighing roller 11 are reset to their initial state, waiting for the transfer of the next full material basket. At the same time, the first roller 1 continues to receive empty material baskets hoisted from the outside. Repeat steps S1 to S9 to realize the self-circulation of the material basket in the connecting process.

2. The self-circulating material basket method for the connecting process according to claim 1, characterized in that, In step S1, before the first roller conveyor 1 receives the empty material basket, it performs a compatibility test on the external dimensions of the empty material basket. Only empty material baskets whose external dimensions meet the preset standards are allowed to enter the first roller conveyor 1. The first roller conveyor 1 limits and guides the empty material basket through adjustable side baffles to ensure that the empty material basket is conveyed along the preset center line.

3. The tandem process basket self-circulation method according to claim 1, characterized by, In step S4, before the transition roller 4 drives the empty material basket to turn, it first detects the real-time status of the first lifting and rotating roller 5. Only when the first lifting and rotating roller 5 is idle and reset to the preset receiving posture will the turning action be started. During the turning process, the offset of the empty material basket is corrected in real time to ensure that the empty material basket accurately enters the first lifting and rotating roller 5.

4. The method according to claim 1, wherein In step S5, after the first lifting and rotating roller conveyor 5 transfers the empty material basket to the receiving tray 8, it confirms whether the empty material basket is completely in place by the distance detection element. If it is not completely in place, the first lifting and rotating roller conveyor 5 performs a replenishment action, pushing the empty material basket to the preset working position of the receiving tray 8. After the replenishment is completed, the first lifting and rotating roller conveyor 5 resets.

5. The method according to claim 1, wherein In step S6, before the full basket is transferred to the second lifting and rotating roller conveyor 9, the material coverage detection element detects the coverage range of the material in the basket. Only after confirming that the material coverage range has reached the preset full material standard is the transfer action to the second lifting and rotating roller conveyor 9 started. During the transfer process, a flexible pushing method is used to avoid impacting the material in the basket.

6. The tandem process basket self-circulation method according to claim 1, wherein In step S8, when the platform scale 12 weighs the full basket, the lifting weighing roller 11 is kept stationary. After the weighing data stabilizes for a preset time, the weight data is locked and recorded. At the same time, the weight data is synchronized to the associated storage unit. After the weighing is completed, a unique corresponding weight identifier is generated and bound to the basket.

7. The method according to claim 1, wherein the method is characterized by, In step S9, when the discharge channel 13 is conveying a full basket, the stacking height of the baskets in the pre-storage area is detected in real time. When the stacking height of the baskets in the pre-storage area reaches a preset threshold, the discharge channel 13 automatically adjusts the conveying direction and conveys the full basket to the backup pre-storage area. The full baskets are arranged in an orderly stacked manner in the pre-storage area.

8. The method according to claim 1, wherein the method is characterized by, Between steps S3 and S4, an additional step is added to detect the flatness of the load-bearing surface of the empty material basket. The flatness detection element detects the load-bearing surface of the empty material basket. If the flatness of the load-bearing surface exceeds the preset allowable range, the empty material basket is diverted to the abnormal material basket storage area to avoid affecting the subsequent material loading quality.

9. The method according to claim 1, wherein the method is characterized by, Throughout all conveying steps, the conveying resistance data of each roller conveyor is collected in real time. The driving force of the roller conveyor is dynamically adjusted based on the conveying resistance data. When the conveying resistance exceeds the preset safety range, the conveying action of the corresponding roller conveyor is stopped immediately and a warning signal is issued. The conveying is restarted only after the resistance returns to normal.

10. The method according to claim 1, wherein It also includes process coordination and linkage steps, real-time collection of production rhythm data of the connecting process, and dynamic adjustment of the conveying speed of each roller, the operating frequency of the lifting mechanism and the allocation strategy of the pre-stored area based on the production rhythm data, so that the self-circulation speed of the material basket matches the production rhythm of the connecting process, and achieves coordinated and efficient operation of the whole process.

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