Automatic cleaning line continuous feeding control method and system based on multi-sensor fusion

Abstract

The invention provides an automatic cleaning line continuous feeding control method and system based on multi-sensor fusion, and the method comprises the steps: comprehensively judging whether an automatic line enters a cleaning frame replacement working condition or not according to an obtained multi-source state signal; when it is judged that the automatic line enters the cleaning frame to replace the working condition, the front-end conveying device is controlled to keep continuous operation, and the aluminum shells output by the shaping device are temporarily stored in a temporary storage unit; the material taking rhythm of the feeding manipulator is synchronously adjusted, so that the material taking rhythm is matched with the conveying rhythm of the front-end conveying device in real time; and when the cleaning frame is replaced and the to-be-treated aluminum shell exists in the cache unit, the feeding manipulator is controlled to take materials from the cache unit preferentially until the cache unit is emptied, and then the materials are directly taken from the shaping device. According to the automatic cleaning line continuous feeding control method and system based on multi-sensor fusion, accurate working condition judgment is achieved through multi-sensor fusion, feeding interruption in the cleaning frame replacement period is eliminated through cache temporary storage and rhythm cooperation, and the production line continuity and efficiency are improved.

Description

Technical Field

[0001] This invention relates to the field of automated production line control technology, and in particular to a continuous feeding control method and system for an automated cleaning line based on multi-sensor fusion. Background Technology

[0002] In the manufacturing of power batteries and consumer electronics, metal workpieces such as aluminum shells require a cleaning process after processing to remove surface oil, chips, and residues to meet the cleanliness requirements of subsequent processes. In automated cleaning lines, cleaning frames, acting as carriers for workpieces entering the cleaning device, have a fixed loading capacity. When a cleaning frame is full, it needs to be replaced with an empty one. During this replacement process, the loading robot cannot place more workpieces into the cleaning frame. Current technologies generally employ a fixed-cycle control method, where the loading robot performs picking and unloading actions at pre-set fixed time intervals. This method cannot dynamically adjust according to actual working conditions such as cleaning frame replacement and changes in incoming materials, forcing the front-end conveyor to stop and wait during cleaning frame replacement, resulting in production line interruptions and efficiency losses.

[0003] In view of this, there is an urgent need for a continuous feeding control method and system for automated cleaning lines based on multi-sensor fusion, in order to at least solve the above-mentioned shortcomings. Summary of the Invention

[0004] One of the objectives of this invention is to provide a continuous feeding control method and system for an automated cleaning line based on multi-sensor fusion. By using multi-sensor fusion, the system can accurately determine the working conditions and eliminate feeding interruptions during cleaning frame replacement through buffering and cycle time coordination, thereby improving the continuity and efficiency of the production line.

[0005] The continuous feeding control method for automated cleaning lines based on multi-sensor fusion provided in this invention includes: A feeding system applicable to a front-end conveying device, a shaping device, a feeding robot, a cleaning device, and a buffer unit includes the following steps: Acquire multi-source status signals, which include at least the material presence status signal at the material picking station, the operating status signal of the front-end conveying device, the occupancy status signal of the buffer unit, and the replacement status signal of the cleaning box. The automatic line determines whether to enter the cleaning frame replacement condition based on a comprehensive assessment of multiple status signals. When it is determined that the automatic line has entered the cleaning frame replacement condition, the control of the front-end conveying device is kept running continuously, and the aluminum shell output by the shaping device is temporarily stored in the buffer unit; The picking rhythm of the loading robot is adjusted synchronously to match the picking rhythm with the conveying rhythm of the front-end conveying device in real time; When the cleaning frame is replaced and there are aluminum shells to be processed in the buffer unit, the feeding robot is controlled to take materials from the buffer unit first, until the buffer unit is emptied and then the material is taken directly from the shaping device.

[0006] Preferably, the automatic line determines whether to enter the cleaning frame replacement condition based on a comprehensive assessment of multi-source status signals, including: When the following conditions are met simultaneously for a preset duration, the automatic line is determined to enter the cleaning box replacement mode: The positioning signal of the cleaning frame is not in position, the load signal of the main drive mechanism of the cleaning device changes abruptly, and the occupancy status signal of the buffer unit indicates that it is idle.

[0007] Preferably, the synchronous adjustment of the material handling cycle of the feeding robot includes: The stacking status of aluminum shells in the buffer unit is monitored using a non-contact detection device. When the accumulation exceeds the first threshold, the picking frequency of the loading robot is increased; when the accumulation is below the second threshold, the picking frequency of the loading robot is decreased. The first threshold is greater than the second threshold to form a hysteresis control interval.

[0008] Preferably, the cache unit is equipped with an attitude maintenance mechanism, which is configured to maintain the preset attitude of the aluminum shell by means of air buoyancy support or vibration during the temporary storage of the aluminum shell.

[0009] The continuous feeding control method for automated cleaning lines based on multi-sensor fusion provided in this embodiment of the invention further includes: Within a preset time window before the cleaning frame arrives at the replacement station, the replacement time of the cleaning frame is predicted by identifying the cleaning frame's identifier. The conveying speed of the front-end conveyor is adjusted in advance based on the predicted replacement time of the cleaning frame, so that the actual capacity of the buffer unit is greater than the total material output of the front-end conveyor during the predicted replacement time.

[0010] Preferably, the buffer unit includes a liftable support platform, and the step of temporarily storing the aluminum shell output by the shaping device into the buffer unit includes: When changing non-cleaning frames, keep the load-bearing platform below the working plane; When the cleaning frame replacement condition is determined, the lifting mechanism is controlled to drive the carrying platform to the material picking height to receive and temporarily store the aluminum shell.

[0011] Preferably, the buffer unit includes a flexible conveyor belt, and the step of temporarily storing the aluminum shells output from the shaping device into the buffer unit includes: Control the flexible conveyor belt to run at a first speed to receive the aluminum shell; When the buffer demand increases, the running speed of the flexible conveyor belt is reduced to the second speed, so that the aluminum shell forms a density accumulation zone on the flexible conveyor belt, and the buffer storage function is achieved by using the speed difference.

[0012] Preferably, the buffer unit includes a primary buffer area and a secondary buffer area arranged sequentially along the material flow direction. The step of temporarily storing the aluminum shell output by the shaping device into the buffer unit includes: The aluminum casing is first directed to the first-level cache for temporary storage; The system monitors the occupancy rate of the first-level cache in real time. When the occupancy rate exceeds 80%, subsequent aluminum casings are diverted to the second-level cache.

[0013] The continuous feeding control method for automated cleaning lines based on multi-sensor fusion provided in this embodiment of the invention further includes: Real-time monitoring of the safety door's open / closed status, the safety light curtain's obstruction status, and the emergency stop switch's trigger status; When it is detected that any safety door switch is open, safety light curtain is blocked, or emergency stop switch is triggered, the power source of the automatic line is immediately cut off and all moving mechanisms are controlled to stop running.

[0014] The continuous feeding control system for an automated cleaning line based on multi-sensor fusion provided in this embodiment of the invention includes: The multi-source status detection module is used to acquire multi-source status signals, which include at least the material presence status signal at the material picking station, the operating status signal of the front-end conveying device, the occupancy status signal of the buffer unit, and the replacement status signal of the cleaning box. The working condition determination module is used to comprehensively determine whether the automatic line should enter the cleaning box to change the working condition based on multi-source status signals. The buffer module is used to control the front-end conveyor to keep running continuously when the automatic line enters the cleaning frame to change working conditions, and to temporarily store the aluminum shells output by the shaping device into the buffer unit. The material handling cycle adjustment module is used to synchronously adjust the material handling cycle of the loading robot, so that the material handling cycle matches the conveying cycle of the front-end conveying device in real time, in order to maintain the continuity of material flow. The feeding module is used to control the feeding robot to prioritize picking up materials from the buffer unit when the cleaning frame has been replaced and there are aluminum shells to be processed in the buffer unit, until the buffer unit is emptied and then it resumes picking up materials directly from the shaping device.

[0015] The beneficial effects of this invention are as follows: This invention comprehensively determines the cleaning frame replacement status by acquiring multiple status signals, including the material presence status signal at the material pick-up station, the operating status signal of the front-end conveyor, the occupancy status signal of the buffer unit, and the cleaning frame replacement status signal. This overcomes the shortcomings of single-signal judgment, such as insufficient dimensions and high misjudgment rate, and improves the accuracy and reliability of status determination. During the cleaning frame replacement, the front-end conveyor is kept running continuously while the aluminum shells are temporarily stored in the buffer unit, avoiding downtime of the front-end conveyor and eliminating feeding interruptions caused by cleaning frame replacement, thus improving the overall cycle efficiency and equipment utilization of the production line. The picking rhythm of the feeding robot is synchronously adjusted to match the conveying rhythm of the front-end conveyor in real time, maintaining the continuity of material flow throughout the cleaning frame replacement process and preventing the aluminum shells from accumulating or becoming disconnected on the conveyor line or buffer unit. After the cleaning frame replacement is completed, the strategy of prioritizing material pick-up from the buffer unit ensures that the buffer unit is emptied and released in a timely manner, allowing the system to quickly return to normal feeding status and preparing buffer space for the next round of cleaning frame replacement, thereby improving the reliability of the system's cyclic operation.

[0016] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in this application.

[0017] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0018] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of a continuous feeding control method for an automated cleaning line based on multi-sensor fusion in an embodiment of the present invention; Figure 2 This is a schematic diagram of an automated cleaning line in an embodiment of the present invention; Figure 3 This is a schematic diagram of a continuous feeding control system for an automated cleaning line based on multi-sensor fusion, as described in an embodiment of the present invention. Detailed Implementation

[0019] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0020] This invention provides a continuous feeding control method for automated cleaning lines based on multi-sensor fusion, applicable to feeding systems including front-end conveying devices, shaping devices, feeding robots, cleaning devices, and buffer units, such as... Figures 1-2 As shown, it includes the following steps: Step 1: Acquire multi-source status signals. The multi-source status signals include at least the material presence status signal of the material picking station, the operating status signal of the front-end conveying device, the occupancy status signal of the buffer unit, and the replacement status signal of the cleaning box.

[0021] The controller acquires the following multi-source status signals in real time via industrial fieldbus or I / O interface: Material presence status signal at the material picking station: Output by a photoelectric sensor located at the discharge end of the shaping device. When there are arranged aluminum shells at the material picking station of the shaping device, the signal is high (material present); when there are no aluminum shells at the material picking station, the signal is low (material absent).

[0022] The operating status signals of the front-end conveyor include the motor operating frequency signal (feedback from the frequency converter), the motor current signal (reflecting the load status), and the conveyor belt speed signal (measured by an encoder). These signals indicate the actual conveying speed of the front-end conveyor, whether it is in operation, and whether the load is normal.

[0023] The occupancy status signal of the buffer unit is output by a group of sensors installed on the buffer unit. It includes a duty signal indicating whether the buffer unit has aluminum shells temporarily stored, and an analog signal indicating the number or occupancy rate of the temporarily stored aluminum shells. For example, multiple position sensors can be used to detect whether each temporary storage position of the buffer unit is occupied, or a vision camera can be used to perform image recognition on the buffer unit to obtain the number and position information of the temporarily stored aluminum shells.

[0024] The replacement status signals of the cleaning frame include the positioning signal of the cleaning frame, the loading signal of the cleaning frame (e.g., counting the number of aluminum shells loaded by a counter, or detecting the loading weight by a weight sensor), and the operating status signal of the main drive mechanism of the cleaning device (reflecting whether the cleaning frame transfer mechanism is performing the frame replacement action).

[0025] Step 2: Based on a comprehensive assessment of multi-source status signals, determine whether the automatic line has entered the cleaning frame replacement phase, including: When the following conditions are met simultaneously for a preset duration, the automatic line is determined to enter the cleaning box replacement mode: The positioning signal of the cleaning frame is not in position, the load signal of the main drive mechanism of the cleaning device changes abruptly, and the occupancy status signal of the buffer unit indicates that it is idle.

[0026] The controller performs comprehensive analysis on the collected multi-source status signals to determine whether the automatic line is currently in the cleaning frame replacement condition. In one specific implementation, when the following three conditions are met simultaneously and the duration reaches a preset time (preset manually, for example, 0.5 seconds to 3 seconds), the controller determines that the automatic line has entered the cleaning frame replacement condition: Condition 1: The positioning signal of the cleaning frame is in an unpositioned state, that is, there is no ready cleaning frame at the current loading station, or the original cleaning frame has been moved away. Condition 2: A sudden change occurs in the load signal of the main drive mechanism of the cleaning device. For example, if the current value of the drive motor changes by more than 15%-30% of the rated current in a short period of time (such as within 0.2 seconds), it indicates that the cleaning frame transfer mechanism is performing frame handling or positioning actions. Condition 3: The occupancy status signal of the buffer unit indicates that it is in an idle state, that is, there is no aluminum shell temporarily stored on the buffer unit, indicating that the buffer unit is ready to receive materials.

[0027] The purpose of setting a preset duration is to filter out misjudgments caused by instantaneous signal fluctuations. For example, when the cleaning box is moved out of the loading station after loading, the arrival signal will disappear briefly. However, this may not be a replacement condition that requires the activation of buffer mode, but rather a normal box ejection action. By setting the aforementioned preset duration, the normal box ejection and the actual replacement condition can be effectively distinguished.

[0028] Step 3: When it is determined that the automatic line has entered the cleaning frame replacement condition, control the front-end conveying device to keep running continuously and temporarily store the aluminum shell output by the shaping device to the buffer unit.

[0029] When the controller determines that the automatic line has entered the cleaning frame replacement phase, it maintains continuous operation of the front-end conveyor. Unlike existing technologies that stop the front-end conveyor line during cleaning frame replacement, this invention controls the front-end conveyor to continue operating, allowing the aluminum shells output from the upstream process to flow uninterruptedly into the shaping device for arrangement and positioning. This avoids frequent starts and stops of the front-end conveyor, reduces the impact on upstream processes, and prevents the aluminum shells from shifting position or changing orientation due to stagnation on the conveyor line.

[0030] The loading robot is controlled to change the target position for picking up and placing materials. Under normal loading conditions, the loading robot picks up the aluminum shell from the picking station of the shaping device and places it into the cleaning frame. After entering the cleaning frame and changing the working condition, the loading robot picks up the aluminum shell from the picking station and places it into the buffer unit for temporary storage.

[0031] The buffer unit performs corresponding receiving actions according to its specific structural form. For example, for a buffer unit with a liftable support platform structure, the lifting mechanism is controlled to drive the support platform to the material picking height; for a buffer unit with a flexible conveyor belt structure, the flexible conveyor belt is controlled to start and run at a set speed.

[0032] Step 4: Synchronously adjust the picking cycle of the loading robot to match the conveying cycle of the front-end conveyor in real time; the synchronous adjustment of the picking cycle of the loading robot includes: The stacking status of aluminum shells in the buffer unit is monitored using a non-contact detection device. When the accumulation exceeds the first threshold, the picking frequency of the loading robot is increased; when the accumulation is below the second threshold, the picking frequency of the loading robot is decreased. The first threshold is greater than the second threshold to form a hysteresis control interval.

[0033] During the cleaning frame replacement process, the accumulation status of aluminum shells in the buffer unit is continuously monitored, and the picking cycle (i.e., picking frequency) of the loading robot is dynamically adjusted accordingly to achieve real-time matching between the picking cycle and the conveying cycle of the front-end conveying device.

[0034] Specifically, the non-contact detection device detects the number or occupancy rate of temporary aluminum shells in the buffer unit in real time and compares it with a preset first threshold and a second threshold. The first threshold is set to 70%-80% of the maximum capacity of the buffer unit, and the second threshold is set to 30%-40% of the maximum capacity of the buffer unit, with the first threshold being greater than the second threshold.

[0035] When the detected accumulation exceeds the first threshold, it indicates that there are too many aluminum shells temporarily stored in the buffer unit and the buffer space is becoming tight. The main controller sends an acceleration picking command to the loading robot controller to increase the picking frequency of the loading robot and speed up the removal of aluminum shells from the buffer unit.

[0036] When the detected accumulation state is below the second threshold, it indicates that the number of aluminum shells temporarily stored in the buffer unit is small and the buffer space is sufficient. The main controller sends a deceleration and material handling command to the loading robot controller to reduce the material handling frequency of the loading robot.

[0037] When the stacking state is between the second threshold and the first threshold, the main controller keeps the current material handling frequency of the loading robot unchanged.

[0038] The design that the first threshold is greater than the second threshold forms a hysteresis control range, which avoids frequent switching of the material handling frequency of the loading robot when the stacking state fluctuates around a single threshold. This reduces the oscillation of the control system and the frequent speed adjustment of the robot, and improves the stability of the system operation.

[0039] By dynamically adjusting the material handling cycle, real-time matching between the material handling cycle of the loading robot and the conveying cycle of the front-end conveying device is achieved during the cleaning frame replacement. When the material arrival rate at the front end is fast, leading to increased buffer accumulation, the material handling frequency is increased to speed up the digestion process; when the material arrival rate at the front end is slow, leading to reduced buffer accumulation, the material handling frequency is reduced to save energy and reduce mechanical wear.

[0040] Step 5: When the cleaning frame is replaced and there are aluminum shells to be processed in the buffer unit, control the feeding robot to take materials from the buffer unit first, until the buffer unit is emptied and then resume taking materials directly from the shaping device.

[0041] When the main drive mechanism delivers the empty cleaning frame to the loading station and the cleaning frame positioning mechanism completes the positioning and locking, the positioning sensor outputs a high-level signal, indicating that the cleaning frame replacement is complete.

[0042] Once the main controller detects that the signal from the positioning sensor changes from low to high and confirms that the main drive mechanism has returned to standby mode, it determines that the cleaning frame replacement operation is over and the automatic line returns to normal feeding operation.

[0043] When resuming normal feeding operation, the main controller first checks the occupancy status of the buffer unit. If there are still aluminum shells to be processed in the buffer unit (occupancy status is not idle), the controller controls the feeding robot to prioritize taking materials from the buffer unit and placing them into the cleaning box, rather than taking materials directly from the material handling station.

[0044] The priority material retrieval strategy continues until all the temporary aluminum shells in the buffer unit are retrieved and the occupied state becomes idle. After that, the main controller switches the material retrieval position of the loading robot back to the material retrieval station, restoring the normal material retrieval mode of directly picking up materials from the shaping device.

[0045] The technical significance of prioritizing material retrieval from the buffer unit is to ensure that the buffer unit is emptied promptly after each cleaning frame replacement cycle, reserving complete buffer space for the next cleaning frame replacement. If priority retrieval is not implemented and material retrieval from the retrieval station is resumed directly, the residual aluminum shells in the buffer unit will remain for a long time, not only occupying buffer space and affecting the buffering capacity of the next cycle, but also potentially affecting the surface quality due to the excessive retention time of the aluminum shells in the buffer area.

[0046] While the aluminum shell is temporarily stored in the buffer unit, it needs to maintain its preset posture (e.g., a vertical posture with the opening facing upwards) so that the loading robot can remove the aluminum shell from the buffer unit in a fixed grasping posture. If the aluminum shell tilts or falls over during the buffering period, the loading robot will be unable to grasp it correctly, affecting subsequent loading operations.

[0047] To address the aforementioned issues, the cache unit is equipped with an attitude maintenance mechanism. The attitude maintenance mechanism can be implemented in two ways: Form 1: Air-float support method. The attitude maintenance mechanism includes multiple air-float holes disposed on the temporary storage surface of the buffer unit, which are connected to a compressed air source. When the buffer unit receives the aluminum shell, compressed air is ejected from the air-float holes to form an air cushion layer, and the aluminum shell is suspended above the air cushion layer. The air-float support reduces the friction between the aluminum shell and the temporary storage surface, allowing the aluminum shell to automatically return to a stable vertical attitude under the fine adjustment of the airflow.

[0048] Form 2: Vibration Maintenance Method. The attitude maintenance mechanism includes a vibration generator installed at the bottom of the buffer unit. The vibration generator produces micro-amplitude high-frequency vibrations with a frequency of 50Hz-200Hz and an amplitude of 0.1mm-0.5mm. This vibration acts on the temporarily stored aluminum shell, causing the slightly tilted aluminum shell to automatically return to a stable vertical posture under vibration excitation, while preventing the aluminum shells from sticking or getting stuck due to static contact.

[0049] The cleaning frames used in automated cleaning lines may come in various specifications and models, and the handling and positioning time required during replacement varies depending on the specifications. Furthermore, due to deformation or wear during long-term use, individual cleaning frames may exhibit variations, and the replacement time may differ even for different frames of the same specification.

[0050] To achieve more precise cache control, this embodiment sets an identification tag on the cleaning box. By recognizing the identification tag, the upcoming cleaning box replacement time is predicted, and the conveying speed of the front-end conveying device is adjusted accordingly. The specific implementation steps are as follows: Each cleaning box is assigned a unique identifier. This identifier can be an RFID tag, a 1D barcode, or a QR code. An identification device is installed at a location before the cleaning box reaches the loading station (e.g., a waiting area upstream of the loading station) to read the identifier.

[0051] The main controller maintains a database of cleaning box replacement times, recording the actual replacement time for each cleaning box during each replacement process. After each cleaning box replacement is completed, the main controller updates the database based on the measured replacement time.

[0052] Within a preset time window before the cleaning frame arrives at the replacement station (e.g., when the cleaning frame arrives at the waiting position), the identification device reads the identification of the cleaning frame. The main controller then queries the database for the historical replacement time of the cleaning frame based on the identification and takes the average or maximum value of the historical replacement time as the predicted replacement time. .

[0053] Based on the predicted replacement time and the actual capacity of the cache unit Calculate the maximum allowable conveying speed of the front-end conveying device. This ensures that the total amount of material output by the front-end conveyor during the predicted replacement period does not exceed the capacity of the buffer unit. ; in, The material output density per unit speed of the front-end conveying device (unit: particles / meter).

[0054] If the current conveying speed of the front-end conveying device Greater than Then the main controller controls the frequency converter to reduce the conveying speed to The following; if Less than or equal to If the speed remains unchanged, then the current speed will remain unchanged.

[0055] Through the above prediction and pre-adjustment mechanism, it is ensured that the actual capacity of the buffer unit is always greater than the total material output of the front-end conveying device within the predicted replacement time, thus avoiding material backlog caused by buffer overflow.

[0056] In this embodiment, the buffer unit includes a support platform and a lifting mechanism. The support platform is a horizontally positioned metal platform with anti-slip textures or positioning grooves on its surface to temporarily store the aluminum shell and prevent it from sliding. The lifting mechanism is a cylinder-driven mechanism or an electric lead screw mechanism, connected to the support platform, and capable of driving the support platform to move vertically up and down.

[0057] During non-cleaning frame replacement operation (normal loading operation), the main controller controls the lifting mechanism to drive the carrying platform to remain in the retracted position below the working plane. At this time, the carrying platform does not interfere with the normal movement trajectory of the loading robot from the material picking station to the cleaning frame loading station.

[0058] When the main controller determines that the automatic line has entered the cleaning frame replacement condition, it sends a lifting command to the lifting mechanism, driving the carrier platform to rise to the material picking height. The material picking height should be set so that the upper surface of the carrier platform is level with or slightly lower than the height of the material picking station, so that the loading robot can move the aluminum shell picked up from the material picking station horizontally and place it directly on the carrier platform.

[0059] Once the cleaning frame replacement is complete and the main controller determines that normal feeding conditions have resumed, the feeding robot first removes the temporarily stored aluminum shells from the support platform and places them into the cleaning frame. After all the aluminum shells on the support platform have been removed, the main controller sends a descent command to the lifting mechanism, driving the support platform back to its retracted position below the working plane.

[0060] The liftable platform type buffer unit retracts without occupying space during normal feeding operations and does not affect normal feeding operations; it only rises to receive materials when buffering is needed, resulting in high space utilization and making it suitable for occasions with compact working spaces.

[0061] In this embodiment, the buffer unit includes a flexible conveyor belt. The flexible conveyor belt is a closed-loop belt conveyor mechanism, positioned between the material handling station and the cleaning frame loading station, with its conveying direction consistent with the material flow direction. The flexible conveyor belt is driven by an independent motor, and its operating speed can be steplessly adjusted via a frequency converter.

[0062] Under normal feeding conditions, the feeding robot grabs the aluminum shell from the picking station and puts it directly into the cleaning frame. The flexible conveyor belt can remain stopped or idle at low speed for standby.

[0063] When the system is determined to be in the cleaning frame replacement phase, the main controller controls the flexible conveyor belt to operate at a first speed. Operation. The loading robot grabs the aluminum shells from the picking station and places them at the feed end of the flexible conveyor belt. The aluminum shells are then transported forward with the flexible conveyor belt and distributed on the conveyor belt, thus achieving a temporary storage function.

[0064] When buffering demand increases (e.g., longer cleaning box replacement time or faster front-end material arrival speed), the main controller controls the flexible conveyor belt's operating speed from the initial speed. Reduce to second speed ,in Less than As the speed decreases, the gap between the aluminum shells placed subsequently on the flexible conveyor belt and the previously placed aluminum shells narrows, forming a density accumulation zone on the flexible conveyor belt. By utilizing the speed difference effect, more aluminum shells can be accommodated on the same conveyor belt length, thus achieving dynamic expansion of buffer storage capacity.

[0065] After the cleaning frame is replaced, the main controller controls the flexible conveyor belt to resume its initial speed. The system operates at or increases its speed to quickly transport the temporarily stored aluminum shells to the discharge end, where they are picked up by the loading robot and placed into the cleaning frame.

[0066] The buffer capacity of the flexible conveyor belt type buffer unit can be dynamically adjusted by adjusting the conveyor belt speed, which is highly flexible; the aluminum shell remains in motion on the conveyor belt, avoiding posture deviation caused by static accumulation.

[0067] In this embodiment, the buffer unit includes a primary buffer zone and a secondary buffer zone arranged sequentially along the material flow direction. The primary buffer zone is located near the material handling station, and the secondary buffer zone is located downstream or to the side of the primary buffer zone. A flow diversion and guiding mechanism is provided at the bifurcation point between the primary and secondary buffer zones. The flow diversion and guiding mechanism can be a pneumatic flap, an electric guide plate, or a push rod mechanism.

[0068] When the system determines that the aluminum shell is ready for replacement in the cleaning box, the main controller will guide it to the primary buffer area for temporary storage by default. The diversion and guiding mechanism remains in the first position, allowing the aluminum shell placed by the loading robot to enter the primary buffer area.

[0069] The main controller monitors the occupancy rate of the primary buffer in real time using sensors installed in the primary buffer. When the occupancy rate exceeds 80%, it indicates that the primary buffer is about to be saturated. The main controller then controls the current distribution guide mechanism to switch to the second position, diverting subsequent aluminum casings to the secondary buffer for temporary storage.

[0070] After the cleaning frame is replaced, the loading robot takes materials from the first-in-first-out buffer area according to the first-in-first-out principle (because the aluminum shells in the first-in-first-out buffer area are temporarily stored first). After the first-in-first-out buffer area is emptied, it takes materials from the second-in-second-out buffer area.

[0071] The setup of primary / secondary buffer units provides a larger total buffer capacity, suitable for applications with long cleaning frame replacement times; the hierarchical temporary storage and first-in-first-out material retrieval order ensure uniform storage time for aluminum shells, preventing some aluminum shells from remaining in place for extended periods.

[0072] To ensure the safety of the feeding process, the automated line is also equipped with safety protection devices, including safety barriers, safety door switches, safety light curtains, and emergency stop switches.

[0073] The safety door switch is a safety switch with a door lock function, installed on each entrance and exit of the safety fence. When the safety door is closed, the safety door switch outputs a closed signal; when the safety door is opened, the safety door switch outputs an open signal.

[0074] The safety light curtain is a through-beam infrared light curtain sensor, installed in passageways where operators may enter the working area of ​​the loading or unloading robot. When there is no obstruction, the safety light curtain outputs a normal signal; when a person or object obstructs the light curtain, the safety light curtain outputs an obstruction signal.

[0075] The emergency stop switches are mushroom-shaped push-button switches with a self-locking function, and are respectively installed on the loading control console, unloading control console, loading robot controller, and unloading robot controller, facilitating emergency stops by operators in different positions. When the emergency stop switch is not pressed, it outputs a closed signal; when pressed, it outputs an open signal and maintains a self-locking state.

[0076] The main controller monitors all the above safety signals in real time. The monitoring logic is as follows: When any safety door switch is detected to be open (safety door is opened), any safety light curtain is blocked, or any emergency stop switch is triggered, the main controller immediately executes the following safety protection actions: Action 1: Cut off the power source of the automated line. The main controller sends a power-off command to the main power contactor, cutting off the power supply to equipment such as the loading robot, unloading robot, and main drive mechanism of the cleaning device.

[0077] Action 2: Stop all motion mechanisms. The main controller sends an emergency stop command to the loading robot controller and the unloading robot controller, causing the robot to immediately stop its current movement.

[0078] Action 3: Issue an audible and visual alarm. The main controller triggers the alarm lights and buzzer to alert on-site personnel to safety.

[0079] The response time of the above safety protection actions is less than 100ms, ensuring that the machine can be stopped in time when personnel accidentally enter dangerous areas or in case of emergency, thus protecting personnel safety.

[0080] Furthermore, the buffer storage function is implemented by utilizing speed differences, including: Under normal conveying conditions, control the flexible conveyor belt at a first speed. During operation, the material is at the first interval Evenly distributed on the conveyor belt; When a cache initiation command is received, the predicted cache duration is obtained. and front-end material receiving rate Calculate the total number of materials that need to be cached. : ; Based on the effective length of the conveyor belt and material width Calculate the target compression gap : ; right Minimum safety clearance constraint shall be applied to ensure that it is not less than ,in This is a pre-set safety clearance; Based on the target compression gap and the first gap The ratio determines the second velocity : ; Control the flexible conveyor belt to follow a preset smooth curve at a preset gradual change time. From the first speed Smoothly switch to second speed The gradual time Based on the coefficient of friction between the material and the conveyor belt surface It is determined that the rate of change of velocity does not exceed The constraints, among which It is the acceleration due to gravity; After the speed switch, the material entering the conveyor belt subsequently will have a spacing smaller than the first gap. The second spacing distributed, This creates a compression zone with a material density higher than normal, enabling dynamic expansion of the buffer capacity. Photoelectric sensors arranged along the conveyor belt detect the time interval between adjacent materials and calculate the actual material spacing. When the actual spacing is less than the preset safe spacing threshold, the conveyor belt speed is increased and a stop discharge signal is sent to the upstream material supply device to prevent material collision. When a buffer release command is received, the release speed is calculated based on the downstream material feeding frequency, and the conveyor belt speed is increased to the release speed so that the material in the compression zone is released in an orderly manner according to the first-in-first-out order. During the caching process, the current quantity of cached materials and the remaining cache capacity are monitored in real time. When the remaining capacity is insufficient, a speed limit command is sent to the front-end conveying device to prevent cache overflow.

[0081] This invention achieves dynamic compression of material spacing by controlling the speed difference of the conveyor belt, thereby increasing buffer capacity without increasing the physical length of the conveyor belt. A smooth speed switching strategy is employed to limit the rate of speed change within the friction constraint range, ensuring that materials do not slip due to inertia. Real-time detection of material spacing using photoelectric sensors, combined with safety threshold judgments, enables anti-collision protection. A remaining buffer capacity monitoring and backpressure adjustment mechanism is established to effectively prevent material accumulation caused by buffer overflow.

[0082] This invention provides a continuous feeding control system for an automated cleaning line based on multi-sensor fusion, such as... Figure 3 As shown, it includes: Multi-source status detection module 1 is used to acquire multi-source status signals, which include at least the material presence status signal of the material picking station, the operating status signal of the front-end conveying device, the occupancy status signal of the buffer unit, and the replacement status signal of the cleaning box. Working condition determination module 2 is used to comprehensively determine whether the automatic line should enter the cleaning frame to change the working condition based on multi-source status signals; Cache module 3 is used to control the front-end conveying device to keep running continuously when the automatic line enters the cleaning frame to change working conditions, and to temporarily store the aluminum shell output by the shaping device to the cache unit. The material handling cycle adjustment module 4 is used to synchronously adjust the material handling cycle of the feeding robot, so that the material handling cycle matches the conveying cycle of the front-end conveying device in real time, in order to maintain the continuity of material flow. The feeding module 5 is used to control the feeding robot to take materials from the buffer unit first when the cleaning frame is replaced and there are aluminum shells to be processed in the buffer unit, until the buffer unit is emptied and then the robot resumes taking materials directly from the shaping device.

[0083] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A continuous feeding control method for an automated cleaning line based on multi-sensor fusion, applied to a feeding system including a front-end conveying device, a shaping device, a feeding robot, a cleaning device, and a buffer unit, characterized in that, Includes the following steps: Acquire multi-source status signals, which include at least the material presence status signal at the material picking station, the operating status signal of the front-end conveying device, the occupancy status signal of the buffer unit, and the replacement status signal of the cleaning box. The automatic line determines whether to enter the cleaning frame replacement condition based on a comprehensive assessment of multiple status signals. When it is determined that the automatic line has entered the cleaning frame replacement condition, the control of the front-end conveying device is kept running continuously, and the aluminum shell output by the shaping device is temporarily stored in the buffer unit. The picking rhythm of the loading robot is adjusted synchronously to match the picking rhythm with the conveying rhythm of the front-end conveying device in real time; When the cleaning frame is replaced and there are aluminum shells to be processed in the buffer unit, the feeding robot is controlled to take materials from the buffer unit first, until the buffer unit is emptied and then the material is taken directly from the shaping device.

2. The continuous feeding control method for an automated cleaning line based on multi-sensor fusion as described in claim 1, characterized in that, The automatic line determines whether to enter the cleaning frame replacement condition based on a comprehensive assessment of multiple status signals, including: When the following conditions are met simultaneously for a preset duration, the automatic line is determined to enter the cleaning box replacement mode: The positioning signal of the cleaning frame is not in position, the load signal of the main drive mechanism of the cleaning device changes abruptly, and the occupancy status signal of the buffer unit indicates that it is idle.

3. The continuous feeding control method for an automated cleaning line based on multi-sensor fusion as described in claim 1, characterized in that, Synchronously adjust the material handling cycle of the loading robot, including: The stacking status of aluminum shells in the buffer unit is monitored using a non-contact detection device. When the accumulation exceeds the first threshold, the picking frequency of the loading robot is increased; when the accumulation is below the second threshold, the picking frequency of the loading robot is decreased. The first threshold is greater than the second threshold to form a hysteresis control interval.

4. The continuous feeding control method for an automated cleaning line based on multi-sensor fusion as described in claim 1, characterized in that, The cache unit is equipped with an attitude maintenance mechanism, which is configured to maintain the preset attitude of the aluminum shell by means of air buoyancy support or vibration during the temporary storage of the aluminum shell.

5. The continuous feeding control method for an automated cleaning line based on multi-sensor fusion as described in claim 1, characterized in that, Also includes: Within a preset time window before the cleaning frame arrives at the replacement station, the replacement time of the cleaning frame is predicted by identifying the cleaning frame's identifier. The conveying speed of the front-end conveyor is adjusted in advance based on the predicted replacement time of the cleaning frame, so that the actual capacity of the buffer unit is greater than the total material output of the front-end conveyor during the predicted replacement time.

6. The continuous feeding control method for an automated cleaning line based on multi-sensor fusion as described in claim 1, characterized in that, The buffer unit includes a liftable support platform. The step of temporarily storing the aluminum shell output from the shaping device into the buffer unit includes: When changing non-cleaning frames, keep the load-bearing platform below the working plane; When the cleaning frame replacement condition is determined, the lifting mechanism is controlled to drive the carrying platform to the material picking height to receive and temporarily store the aluminum shell.

7. The continuous feeding control method for an automated cleaning line based on multi-sensor fusion as described in claim 1, characterized in that, The buffer unit includes a flexible conveyor belt, and the step of temporarily storing the aluminum shells output from the shaping device into the buffer unit includes: Control the flexible conveyor belt to run at a first speed to receive the aluminum shell; When the buffer demand increases, the running speed of the flexible conveyor belt is reduced to the second speed, so that the aluminum shell forms a density accumulation zone on the flexible conveyor belt, and the buffer storage function is achieved by using the speed difference.

8. The continuous feeding control method for an automated cleaning line based on multi-sensor fusion as described in claim 1, characterized in that, The buffer unit includes a primary buffer area and a secondary buffer area arranged sequentially along the material flow direction. The step of temporarily storing the aluminum shells output from the shaping device into the buffer unit includes: The aluminum casing is first directed to the first-level cache for temporary storage; The system monitors the occupancy rate of the first-level cache in real time. When the occupancy rate exceeds 80%, subsequent aluminum casings are diverted to the second-level cache.

9. The continuous feeding control method for an automated cleaning line based on multi-sensor fusion as described in claim 1, characterized in that, Also includes: Real-time monitoring of the safety door's open / closed status, the safety light curtain's obstruction status, and the emergency stop switch's trigger status; When it is detected that any safety door switch is open, safety light curtain is blocked, or emergency stop switch is triggered, the power source of the automatic line is immediately cut off and all moving mechanisms are controlled to stop running.

10. A continuous feeding control system for an automated cleaning line based on multi-sensor fusion, characterized in that, include: The multi-source status detection module is used to acquire multi-source status signals, which include at least the material presence status signal of the material picking station, the operating status signal of the front-end conveying device, the occupancy status signal of the buffer unit, and the replacement status signal of the cleaning box. The working condition determination module is used to comprehensively determine whether the automatic line should enter the cleaning box to change the working condition based on multi-source status signals. The buffer module is used to control the front-end conveyor to keep running continuously when the automatic line enters the cleaning frame to change working conditions, and to temporarily store the aluminum shells output by the shaping device into the buffer unit. The material handling cycle adjustment module is used to synchronously adjust the material handling cycle of the loading robot, so that the material handling cycle matches the conveying cycle of the front-end conveying device in real time, in order to maintain the continuity of material flow. The feeding module is used to control the feeding robot to prioritize picking up materials from the buffer unit when the cleaning frame has been replaced and there are aluminum shells to be processed in the buffer unit, until the buffer unit is emptied and then it resumes picking up materials directly from the shaping device.

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