An automatic sorting system and method for electrical fittings

Abstract

This invention discloses an automatic sorting system and method for power fittings, relating to the field of fitting sorting. The system includes: configuring online workstations for bag opening and box feeding; configuring an online conveyor section composed of a telescopic belt and a conveyor belt; and setting up a protective structure and operational status acquisition mechanism for the front-end conveyor section. The system uses a quick-change fixture architecture to seamlessly switch between dedicated individual fitting fixtures, carton suction cup fixtures, turnover box fixtures, and burlap sack fixtures. It incorporates candidate gripping posture, category confidence, placement acceptance consistency, and cycle time compliance into the unified release logic of the electrical control system. In case of anomalies, the system switches to a temporary offline manual processing position and restores online operation, thereby maintaining a sorting accuracy of no less than 99% and a stable output of 5 pieces / min and 5 boxes / min. On the discharge side, the system uses an automatic guided transport vehicle with a repeatability accuracy of ±10mm and an angle deviation of ±1° as a benchmark. Combined with a double-reconnection upper limit and a safety light curtain emergency stop closed loop, it achieves consistent palletized handover and safe coordination in the work area.

Description

Technical Field

[0001] This invention relates to the field of hardware sorting, and in particular to an automatic sorting system and method for power hardware. Background Technology

[0002] Power fittings exhibit the characteristics of multi-category, small-batch, and frequent turnover in the warehousing and maintenance of power supply enterprises. In the inbound and outbound processes, there is often a mixture of three types of carriers, namely cardboard boxes, woven bags, and turnover boxes, as well as various models of fittings. In order to achieve continuous feeding and stable supply, the on-site configuration of bag / box unpacking and feeding box online station is connected to the online conveyor section composed of telescopic belt and belt conveyor. The telescopic belt meets the requirements of maximum retracted length not exceeding 5000mm, maximum extended length not less than 11000mm, and unit length load capacity not less than 60kg / m. The operating status is collected by material detection, telescopic position, and deviation sensors to form the front-end conveyor foundation for automatic sorting.

[0003] Current sorting methods rely heavily on manual depalletizing and visual picking. When faced with randomly stacked hardware in turnover boxes, issues such as hooking, overlapping, and ungraspable postures can easily occur. Blind grabbing leads to grabbing failures and induces secondary hooking. It is difficult to simultaneously meet the requirements of sorting accuracy and cycle stability. At the same time, mixed carriers lack standardized quick-change and adaptation judgment of gripping fixtures. After sorting, there is a lack of category and placement consistency verification and abnormal isolation closed loop. It is also difficult to link cycle exceeding limits, positioning deviations, and emergency safety stops, resulting in the accumulation of time spent on missorting rework and line recovery. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing technologies by providing an automatic sorting system and method for power fittings. The method utilizes a 3D camera to output a set of candidate grasping poses during the sorting stage. It employs anti-clamping grasping feasibility to determine the release of grasping poses. If the release conditions are not met, a closed-loop manual processing and temporary storage position diversion is triggered. Simultaneously, a dual-channel path for magnetic attraction-enhanced fault tolerance and clamping grasping is constructed. The magnetic attraction path uses a 15° attitude deviation threshold to prevent blind grasping and uses a category confidence threshold of 0.92 to drive the category-positioning mapping table for placement. Combined with a single-cycle action time threshold of 20 seconds, a rhythmic release control is formed, reducing clamping and missorting from the source.

[0005] Therefore, this application provides an automatic sorting system and method for power fittings, comprising the following steps: Step S100: Configure the bag opening and box feeding station, configure the online conveyor section consisting of telescopic belt and belt line, and set the front-end conveyor section protection structure and operation status acquisition mechanism.

[0006] Step S200: Configure the shuttle garage front area and hardware sorting robotic arm, configure the clamp quick change device and clamp system, set the clamp matching judgment formula and clamp switching link, and set the clamp size threshold and sorting operation indicators.

[0007] Step S300: Configure the visual recognition module's three-dimensional imaging unit and the gripping operation support structure; set the candidate gripping pose set judgment and offline manual processing temporary storage position diversion mechanism; set the magnetic attraction enhanced fault-tolerant gripping path and clamping gripping path; set the anti-snagging gripping feasibility formula and component material rules.

[0008] Step S400: Configure the coordinated layout of the offline conveyor line, inspection and sorting station, material discharge station and offline manual processing temporary storage station; set the single cycle cycle constraint of the hardware sorting robot arm and the clamp action cycle parameters; set the cycle compliance formula and cycle release threshold.

[0009] Step S500: Establish a sorting classification set and a category-placement mapping table, perform category label release judgment and target placement selection, and perform customized fixture gripping, placement acceptance and anomaly isolation.

[0010] Step S600: Set the docking rules and pallet guiding correction structure for the unloading station-automatic guided transport vehicle, configure the docking positioning deviation measurement and positioning correction closed-loop release judgment, and configure the safety light curtain emergency stop link and abnormal recovery online process.

[0011] In some specific embodiments, step S100 specifically includes: Step S100.1: Configure the bag unpacking and box feeding box online station, and configure the online conveyor section composed of telescopic belt and belt line.

[0012] Step S100.1: Set the front-end conveyor section protection structure and operation status acquisition mechanism.

[0013] A protective structure is set for the front-end conveying section. Protective railings are installed around the conveyor belt and rollers, and protective covers are installed on the outside of the protective railings. The height of the protective railings is set to be no less than 1.2m, and the structural gap of the protective railings is set to be no more than 8mm. Protective baffles are installed in the movement area of ​​the telescopic mechanism, and the protective baffles cover the extension stroke area and retraction stroke area of ​​the telescopic mechanism.

[0014] An operational status acquisition mechanism is set up, with material detection sensors, telescopic position sensors, and belt misalignment sensors installed in the front-end conveyor section. The material detection sensors output the arrival signal of cartons, woven bags, and turnover boxes entering the telescopic belt, the telescopic position sensors output the extension length status of the telescopic belt, and the belt misalignment sensors output the belt misalignment status.

[0015] In some specific embodiments, step S200 specifically includes: Step S200.1: Configure the shuttle garage front area and hardware sorting robotic arm, configure the quick-change device and fixture system, and set the fixture matching judgment formula and fixture switching link.

[0016] Step S200.2: Set the fixture size threshold and sorting operation indicators.

[0017] Set the clamp size thresholds: the cardboard box suction cup clamp is set to a cardboard box size threshold of no more than 600×500×500mm, the turnover box clamp is set to a turnover box size threshold of no more than 600×400×400mm, and the burlap sack clamp is set to a woven bag size threshold of no more than 600×400×300mm.

[0018] Set sorting operation indicators: sorting accuracy is set to no less than 99%, sorting efficiency is set to 5 items / min and 5 boxes / min. The electrical control system records the sorting accuracy statistics and sorting efficiency statistics. The sorting accuracy statistics are used to constrain the output stability of the vision recognition module, and the sorting efficiency statistics are used to constrain the switching cycle stability of the quick-change fixture.

[0019] In some specific embodiments, step S300 specifically includes: Step S300.1: Configure the visual recognition module's three-dimensional imaging unit and the grasping operation support structure; set the candidate grasping pose set judgment and offline manual processing temporary position diversion mechanism; set the magnetic attraction enhanced fault-tolerant grasping path and clamping grasping path.

[0020] Step S300.2: Set the formula for the feasibility of anti-snagging and grabbing and the rules for dividing materials.

[0021] In some specific embodiments, step S400 specifically includes: Step S400.1: Configure the coordinated layout of the offline conveyor line, inspection and sorting station, material discharge station and offline manual processing temporary storage station, and set the single cycle cycle constraint of the hardware sorting robot arm and the clamp action cycle parameters.

[0022] Step S400.2: Set the beat compliance formula and beat release threshold.

[0023] Set the timer release threshold; the timer release threshold is set to... Electrical control system judgment The electrical control system determines that the robot's grasping action is in the open state. It outputs an alarm signal and transfers the turnover box to the offline manual processing temporary storage position.

[0024] In some specific embodiments, S500 specifically includes: Step S500.1: Establish a sorting classification set and category location mapping table, and perform category label release judgment and target location selection.

[0025] Step S500.2: Perform customized fixture gripping, placement acceptance and anomaly isolation.

[0026] The robot performs customized gripping. It is equipped with a special hardware fixture and has adjustable mechanical jaws and contoured contact surfaces. The opening stroke of the adjustable mechanical jaws is set from 20mm to 160mm. The contoured contact surfaces are used to fit the clamping features of tension clamps NLD-4, NLD-3, NLD-2, bowl head hangers W-7B and WS-10, U-shaped hanging rings U-25 and U-shaped hanging rings U-7, wedge clamps NX-2, UT clamps NUT-2, and Z-shaped hanging rings Z-7. The special hardware fixture adopts a high-strength alloy structure and outputs the measured clamping force value. The clamping force range corresponding to the measured clamping force value is set from 120N to 450N.

[0027] The robot body performs magnetic suction-enhanced fault-tolerant gripping. During the gripping actions of ball-head ring QP-7, ball-head ring QP-10 and extension ring PH-10, the robot body is equipped with magnetic chucks with a diameter of 80mm and picks up the flat surface. The magnetic chuck adsorption and holding time is set to be no less than 0.30s. After the magnetic chuck adsorption and holding time is met, the robot body performs the transportation action and the placement action.

[0028] During the placement acceptance process, the electrical control system uses the placement acceptance formula to determine the consistency between the placement results of the sorting station and the pallet station at the discharge station.

[0029] Set the placement acceptance threshold; the placement acceptance threshold is set to... Electrical control system judgment The electrical control system determines whether to release the palletized handover process at the material unloading station. When the abnormality of the inspection and sorting station is detected, an alarm signal is output. After the abnormality of the inspection and sorting station is detected, the turnover box is transferred to the offline manual processing temporary storage position to form an abnormal closed link.

[0030] In some specific embodiments, step S600 specifically includes: Step S600.1: Set the docking rules and pallet guiding correction structure for the unloading station-automatic guided transport vehicle, and configure the docking positioning deviation measurement and positioning correction closed-loop release judgment.

[0031] Step S600.2: Configure the safety light curtain emergency stop link and abnormal recovery connection process.

[0032] A safety light curtain is introduced and positioned at the perimeter of the working area of ​​the hardware sorting robot arm, forming a safety interlock input. A robot control cabinet and an electrical control system control cabinet are also introduced. The robot control cabinet drives the robot body, while the electrical control system control cabinet executes control of the conveyor section, the inspection and sorting station, and the unloading station. The safety light curtain is connected to the emergency stop link between the robot control cabinet and the electrical control system control cabinet, forming a safety interlock closed loop. The response time from the safety light curtain triggering the emergency stop link action is set to no more than 50ms, and the stopping time from the emergency stop link action to the robot body stopping is set to no more than 0.50s.

[0033] On-site usage constraints are set: the noise level of the hardware sorting robot arm is set to less than 75dB, the protection level of the hardware sorting robot arm is set to IP65, and the electrical control system maintains the compliance of the hardware sorting robot arm's operation based on the noise monitoring value and the protection level setting value.

[0034] An abnormal interlocking handling process is set up. After the safety light curtain trigger signal, the alarm signal triggered by the cycle time compliance being less than the cycle time release threshold, the alarm signal triggered by the category confidence being less than the category confidence threshold, and the alarm signal triggered by the placement acceptance consistency value being less than the placement acceptance threshold enter the electrical control system, the electrical control system outputs that the conveyor line suspends control actions and keeps the robot body's grasping action in the release closed state. The electrical control system transfers the turnover box to the offline manual processing temporary storage position and maintains the offline manual processing temporary storage position in an isolated state.

[0035] An automatic sorting system for power fittings includes the following modules: The feeding module is used to configure the bag-opening and box-feeding station, configure the conveyor section consisting of telescopic belts and belt conveyors, and set the protection structure and operation status acquisition mechanism of the front-end conveyor section.

[0036] The sorting execution module is used to configure the shuttle garage front area and hardware sorting robotic arm, configure the clamp quick change device and clamp system, set the clamp matching judgment formula and clamp switching link, and set the clamp size threshold and sorting operation indicators.

[0037] The vision grasping module is used to configure the 3D imaging unit of the vision recognition module and the grasping operation support structure, set the candidate grasping pose set judgment and offline manual processing temporary storage position diversion mechanism, set the magnetic attraction enhanced fault-tolerant grasping path and clamping grasping path, set the anti-snagging grasping feasibility formula and component material rules.

[0038] The cycle time coordination module is used to configure the coordinated layout of the offline conveyor line, inspection and sorting station, unloading station and offline manual processing temporary storage station, set the single cycle time constraint of the hardware sorting robot arm and the clamp action cycle time parameters, and set the cycle time compliance formula and cycle time release threshold.

[0039] The sorting and placement module is used to establish sorting categories and category-placement mapping tables, perform category label release judgment and target placement selection, and perform customized fixture gripping, placement acceptance and anomaly isolation.

[0040] The material discharge interlock module is used to set the docking rules between the material discharge station and the automatic guided transport vehicle, as well as the pallet guiding and correction structure. It also configures the docking positioning deviation measurement and positioning correction closed-loop release judgment, and the safety light curtain emergency stop link and abnormal recovery online process.

[0041] In summary, the automatic sorting system and method for power fittings provided in this application enable the orderly switching of dedicated single-piece fitting clamps, cardboard box suction cup clamps, turnover box clamps, and sack clamps using a quick-change clamp architecture. The system incorporates candidate gripping posture, category confidence, placement acceptance consistency, and cycle time compliance into the unified release logic of the electrical control system. In case of abnormalities, the system switches to a temporary storage position for manual processing and restores online operation, thereby maintaining a sorting accuracy of not less than 99% and a stable output of 5 pieces / min and 5 boxes / min. On the discharge side, the system uses the automatic guided transport vehicle's repeatability accuracy of ±10mm and angle deviation of ±1° as a benchmark, combined with a double re-connection limit and a safety light curtain emergency stop closed loop, to achieve palletized handover consistency and safe collaboration in the work area. Attached Figure Description

[0042] Figure 1 This is an overall flowchart of an automatic sorting method for power fittings provided in an embodiment of this application.

[0043] Figure 2 This is an overall framework diagram of an automatic sorting system for power fittings provided in an embodiment of this application. Detailed Implementation

[0044] Please refer to Figure 1 The diagram illustrates a flow chart of an embodiment of an automatic sorting system and sorting method for power fittings according to the present disclosure.

[0045] like Figure 1 As shown, an automatic sorting system and method for electrical fittings includes the following steps: Step S100: Configure the bag opening and box feeding station, configure the online conveyor section consisting of telescopic belt and belt line, and set the front-end conveyor section protection structure and operation status acquisition mechanism.

[0046] Step S200: Configure the shuttle garage front area and hardware sorting robotic arm, configure the clamp quick change device and clamp system, set the clamp matching judgment formula and clamp switching link, and set the clamp size threshold and sorting operation indicators.

[0047] Step S300: Configure the visual recognition module's three-dimensional imaging unit and the gripping operation support structure; set the candidate gripping pose set judgment and offline manual processing temporary storage position diversion mechanism; set the magnetic attraction enhanced fault-tolerant gripping path and clamping gripping path; set the anti-snagging gripping feasibility formula and component material rules.

[0048] Step S400: Configure the coordinated layout of the offline conveyor line, inspection and sorting station, material discharge station and offline manual processing temporary storage station; set the single cycle cycle constraint of the hardware sorting robot arm and the clamp action cycle parameters; set the cycle compliance formula and cycle release threshold.

[0049] Step S500: Establish a sorting classification set and a category-placement mapping table, perform category label release judgment and target placement selection, and perform customized fixture gripping, placement acceptance and anomaly isolation.

[0050] Step S600: Set the docking rules and pallet guiding correction structure for the unloading station-automatic guided transport vehicle, configure the docking positioning deviation measurement and positioning correction closed-loop release judgment, and configure the safety light curtain emergency stop link and abnormal recovery online process.

[0051] In some specific embodiments, step S100 specifically includes: Step S100.1: Configure the bag unpacking and box feeding box online station, and configure the online conveyor section composed of telescopic belt and belt line.

[0052] Configure a bag / box unpacking and feeding station. The bag / box unpacking and feeding station is used to receive three types of feeding carriers: cartons, woven bags and turnover boxes, and to align the shape and posture of cartons, woven bags and turnover boxes before they are put into service.

[0053] The bag / box feeding station is equipped with a feeding guide and limit structure. The feeding guide and limit structure limits the feeding direction of cartons, woven bags and turnover boxes. The feeding guide and limit structure is aligned with the center line of the upper conveyor section to ensure the stability of the posture of cartons, woven bags and turnover boxes when they enter the upper conveyor section.

[0054] The system is configured with an online conveyor section, which consists of a telescopic belt and a conveyor belt. The telescopic belt is located on the discharge side of the bag / box feeding station, and the conveyor belt is located on the receiving side of the telescopic belt.

[0055] The maximum retracted length of the telescopic belt is set to no more than 5000mm, the maximum extended length of the telescopic belt is set to no less than 11000mm, the load capacity per unit length of the telescopic belt is set to no less than 60kg / m, and the telescopic belt is equipped with an adjustable height structure, which is used to adjust the height of the conveyor surface of the telescopic belt so that the conveyor surface of the telescopic belt and the conveyor surface of the belt line are kept at the same height reference.

[0056] Step S100.1: Set the front-end conveyor section protection structure and operation status acquisition mechanism.

[0057] A protective structure is set for the front-end conveying section. Protective railings are installed around the conveyor belt and rollers, and protective covers are installed on the outside of the protective railings. The height of the protective railings is set to be no less than 1.2m, and the structural gap of the protective railings is set to be no more than 8mm. Protective baffles are installed in the movement area of ​​the telescopic mechanism, and the protective baffles cover the extension stroke area and retraction stroke area of ​​the telescopic mechanism.

[0058] An operational status acquisition mechanism is set up, with material detection sensors, telescopic position sensors, and belt misalignment sensors installed in the front-end conveyor section. The material detection sensors output the arrival signal of cartons, woven bags, and turnover boxes entering the telescopic belt, the telescopic position sensors output the extension length status of the telescopic belt, and the belt misalignment sensors output the belt misalignment status.

[0059] The electrical control system receives status signals from material detection sensors, telescopic position sensors, and misalignment sensors, forming the operating status monitoring input for the front-end conveyor section. Based on the misalignment status signal, it triggers the protective control action of the conveyor section to ensure the stable operation of the online conveyor section.

[0060] In some specific embodiments, step S200 specifically includes: Step S200.1: Configure the shuttle garage front area and hardware sorting robotic arm, configure the quick-change device and fixture system, and set the fixture matching judgment formula and fixture switching link.

[0061] The shuttle garage front area is configured with a hardware sorting and feeding station. The hardware sorting and feeding station is connected to the online conveyor section. After the cardboard boxes, woven bags and turnover boxes enter the hardware sorting and feeding station, they are kept in a grabbable and parking posture.

[0062] A hardware sorting robotic arm is configured, which includes a vision recognition module, a quick-change fixture device, and a robot body. The vision recognition module outputs the target positioning result and the target posture result of the power hardware. The quick-change fixture device carries the fixture system and completes the fixture switching. The robot body performs grasping, transporting, and placing actions based on the target positioning result and the target posture result of the power hardware, forming an automatic sorting execution unit.

[0063] The automated sorting execution unit covers inbound palletizing operations, outbound depalletizing operations, and sorting operations. The inbound palletizing operation unit and the outbound depalletizing operation unit are set for cardboard boxes, woven bags, and turnover boxes.

[0064] The fixture quick-change device includes a fixture quick-change master and slave disk and a standardization module. The fixture quick-change master and slave disk supports a load setting of 350kg, the standardization module supports an input / output point setting of 219 points, the standardization module supports a servo group setting of 4 groups, and the standardization module supports an air path setting of 40 paths.

[0065] A clamping system is set up, which includes special hardware single clamps, cardboard box suction cup clamps, turnover box special clamps and burlap sack special clamps. The special hardware single clamps clamp the power hardware single units, the cardboard box suction cup clamps the cardboard boxes, the turnover box special clamps clamp the turnover boxes, and the burlap sack special clamps clamp the woven bags.

[0066] The rated load of the clamp is set to no more than 50 kg for woven bags, no more than 50 kg for turnover boxes, and no more than 50 kg for cardboard boxes.

[0067] A fixture matching determination formula is set. This formula is used to select and release fixtures among special-purpose hardware single fixtures, cardboard box suction cup fixtures, turnover box special fixtures, and burlap sack special fixtures. The fixture selection and release triggers the fixture quick-change device to complete the fixture switching and output a fixture locking status signal. Specifically: In the formula: It is the first The fixture matching determination value of each fixture. It is a step function. This is the measured value of the length of the feed carrier. This is the measured value of the width of the feed carrier. This is the measured value of the height of the feed carrier. It is the first A permissible length threshold for each fixture. It is the first A permissible width threshold for each fixture. It is the first Each fixture has a permissible height threshold. This is the measured value of the mass of the feed carrier. It is the first Each fixture allows a certain mass threshold. It is the Kronecker function. It is the code for the type of feed carrier. It is the first Each fixture adapter type is encoded.

[0068] The fixture switching link is set up, which includes fixture return to zero position, fixture docking position, fixture locking confirmation and fixture disengagement confirmation. The electrical control system receives the fixture locking status signal and uses the fixture locking status signal as the condition for fixture switching to be completed. After the fixture switching is completed, the electrical control system sends the grasping action control command to the robot body.

[0069] Step S200.2: Set the fixture size threshold and sorting operation indicators.

[0070] Set the clamp size thresholds: the cardboard box suction cup clamp is set to a cardboard box size threshold of no more than 600×500×500mm, the turnover box clamp is set to a turnover box size threshold of no more than 600×400×400mm, and the burlap sack clamp is set to a woven bag size threshold of no more than 600×400×300mm.

[0071] Set sorting operation indicators: sorting accuracy is set to no less than 99%, sorting efficiency is set to 5 items / min and 5 boxes / min. The electrical control system records the sorting accuracy statistics and sorting efficiency statistics. The sorting accuracy statistics are used to constrain the output stability of the vision recognition module, and the sorting efficiency statistics are used to constrain the switching cycle stability of the quick-change fixture.

[0072] In some specific embodiments, step S300 specifically includes: Step S300.1: Configure the visual recognition module's three-dimensional imaging unit and the grasping operation support structure; set the candidate grasping pose set judgment and offline manual processing temporary position diversion mechanism; set the magnetic attraction enhanced fault-tolerant grasping path and clamping grasping path.

[0073] The system is equipped with a 3D imaging unit for visual recognition. The 3D imaging unit uses a 3D camera to perform 3D imaging of the power fittings in the material feeding position of the fitting sorting operation. Based on the 3D imaging results, the visual recognition module outputs the target positioning result of the power fitting, the target posture result of the power fitting, and a set of candidate grasping postures.

[0074] The candidate grasping pose set is established for the material receiving scenario inside the turnover box, which covers the grasping and placement of 7 to 9 types of power fittings by category.

[0075] The robot tooling rack is configured to hold four types of tooling. These four types of tooling are used to support the sequential retrieval of special hardware single clamps, cardboard box suction cup clamps, turnover box special clamps, and burlap sack special clamps.

[0076] A gripper storage platform is configured to store special hardware single clamps, cardboard box suction cup clamps, turnover box special clamps and burlap bag special clamps at fixed points. The hardware sorting robot arm completes the orderly storage and retrieval of clamps based on the gripper storage platform.

[0077] A candidate grasping pose set determination mechanism is set up. The electrical control system receives the candidate grasping pose set. When the electrical control system determines that the candidate grasping pose set is empty, it outputs an alarm signal. The alarm signal triggers the turnover box to be transferred to the offline manual processing temporary storage position.

[0078] The temporary storage area for manual processing after the production line is located in the front area of ​​the shuttle garage and is isolated from the material inlet for the hardware sorting operation. After the turnover box enters the temporary storage area for manual processing after the production line, the robot body stops its gripping action and releases it.

[0079] A magnetically enhanced fault-tolerant gripping path is set up. The magnetically enhanced fault-tolerant gripping path uses a magnetic chuck with a diameter of 80mm as the end gripping component. The magnetic chuck performs a suction action on the flat surface of the power fitting. The magnetically enhanced fault-tolerant gripping path is suitable for ball head hangers QP-7, ball head hangers QP-10, bowl head hangers W-7B, bowl head hangers WS-10, U-shaped hangers U-7, extension rings PH-10 and Z-7.

[0080] The magnetic attraction-enhanced fault-tolerant grasping path is set with a posture deviation angle threshold of 15°. When the posture deviation angle exceeds 15°, the magnetic attraction-enhanced fault-tolerant grasping path is blocked and allowed to proceed, and the process is switched to the candidate grasping pose set for regeneration.

[0081] A clamping and gripping path is set, which uses a pneumatic parallel gripper as the end gripping component. The pneumatic parallel gripper grips the clamping feature parts of the power fittings. The clamping and gripping path is used to handle the gripping of power fittings other than the magnetic attraction enhanced fault-tolerant gripping path. The magnetic attraction enhanced fault-tolerant gripping path and the clamping and gripping path form a dual-channel gripping path.

[0082] Step S300.2: Set the formula for the feasibility of anti-snagging and grabbing and the rules for dividing materials.

[0083] The feasibility calculation for anti-snagging grasping is set. Based on the feasibility formula for anti-snagging grasping, the electrical control system performs a grasping pose release judgment on the candidate grasping pose set, specifically as follows: In the formula: Is it about the feasibility of preventing cross-linking and data scraping? It is the contact surface weighting coefficient. It is the attitude weighting coefficient. It is the gap weighting coefficient. It is the estimated accessible area corresponding to the candidate grasping pose. It is the normalized upper limit of the accessible area. It is the angle of deviation of the candidate capture pose. The attitude deviation angle is a normalized parameter and set to 10°. It is the minimum nearest neighbor gap distance corresponding to the candidate grasp pose. It is the minimum nearest neighbor gap distance normalized parameter and set to 6mm.

[0084] Set the capture pose release threshold; the capture pose release threshold is set to... Electrical control system judgment The system sends a grasping action control command to the robot body, and the electrical control system determines... An alarm signal is output and the turnover box is transferred to the offline manual processing temporary storage position.

[0085] Set rules for component separation. Wedge clamp NX-2 and UT clamp NUT-2 are defined as component separation materials. These materials are stored and handled separately. The spacing between separately stored components is set to be no less than 50mm. Separate handling is performed within the same turnover box, releasing components sequentially according to their serial numbers to reduce the probability of handling failure due to separation. Tension clamps NLD-2, NLD-3, and NLD-4 are defined as high-risk materials for entanglement. High-risk materials are handled in... The process will directly trigger the offline manual processing temporary storage route.

[0086] In some specific embodiments, step S400 specifically includes: Step S400.1: Configure the coordinated layout of the offline conveyor line, inspection and sorting station, material discharge station and offline manual processing temporary storage station, and set the single cycle cycle constraint of the hardware sorting robot arm and the clamp action cycle parameters.

[0087] An offline collaborative layout consisting of an offline conveyor line, a sorting and inspection station, and a discharge station is constructed. The offline conveyor line connects with the placement area of ​​the hardware sorting robot arm. The offline conveyor line undertakes the placement action of the robot body and forms a continuous conveying path.

[0088] The inspection and sorting station is located in the middle of the off-line conveyor. The inspection and sorting station is used to perform random inspection positioning and abnormal isolation. The trigger ratio for random inspection positioning is set to 5%. The trigger conditions for abnormal isolation include an alarm signal triggered when the candidate grasping pose set is empty and an alarm signal triggered when the anti-snagging grasping feasibility is less than the grasping pose release threshold.

[0089] The unloading station is located at the end of the offline conveyor line. The unloading station is used to perform classified unloading and palletized handover. The palletized handover uses a pallet carrier, and the pallet carrier can carry 20 pieces per pallet.

[0090] Configure a temporary storage location for offline manual processing. This location is set up in the front area of ​​the shuttle garage and is isolated from the material inlet of the hardware sorting operation. After the alarm signal triggers the turnover box to be transferred to the temporary storage location for offline manual processing, the electrical control system maintains the robot's gripping action in the release and closing state until the temporary storage location for offline manual processing completes the diversion and returns to a gripping and parking posture.

[0091] A single-cycle action time threshold for the hardware sorting robot arm is set to 20s. Based on the single-cycle action time threshold, the electrical control system performs cycle constraint control on the robot's gripping, transporting, and positioning actions. A lifting and adsorption time threshold is set for the carton gripper made of carton suction cup and the bag gripper made of burlap sack. The lifting and adsorption time threshold is set to 2.5s.

[0092] The robot's linear speed is set to 2 m / s, and the robot's speed coefficient is set to 90%. Under the constraints of the robot's linear speed and speed coefficient, the carton gripper and bag gripper form a single-cycle operation time of approximately 14 seconds.

[0093] The single-cycle action time threshold of the material basket gripper, which is composed of special clamps for turnover boxes, is set to 12s. The single-cycle action time threshold of the material basket gripper is consistent with the sorting efficiency setting of 5 pieces / min and 5 boxes / min.

[0094] A parallel mechanism for 3D camera photography is set up, where the 3D camera photography action and the robot's handling action are kept in parallel. The maximum time occupied by the 3D camera photography action is set to 0.20s, and the 3D camera photography action does not occupy the single loop action time threshold.

[0095] Step S400.2: Set the beat compliance formula and beat release threshold.

[0096] The cycle time compliance calculation is set, and the electrical control system determines the cycle time release of the hardware sorting robot arm based on the cycle time compliance formula, specifically as follows: In the formula: It's about rhythm compliance. The single-loop action time threshold is set to 20 seconds. This is the actual single-cycle action time of the hardware sorting robot arm.

[0097] Set the timer release threshold; the timer release threshold is set to... Electrical control system judgment The electrical control system determines that the robot's grasping action is in the open state. It outputs an alarm signal and transfers the turnover box to the offline manual processing temporary storage position.

[0098] In some specific embodiments, S500 specifically includes: Step S500.1: Establish a sorting classification set and category location mapping table, and perform category label release judgment and target location selection.

[0099] Establish a sorting classification set, which includes tension clamp NLD-4, tension clamp NLD-3, tension clamp NLD-2, bowl head hanging plate W-7B, bowl head hanging plate WS-10, ball head hanging ring QP-7, ball head hanging ring QP-10, U-shaped hanging ring U-25, U-shaped hanging ring U-7, extension ring PH-10, wedge clamp NX-2, UT clamp NUT-2, and Z-shaped hanging ring Z-7.

[0100] A category placement mapping table is established and stored by the electrical control system. The entries in the category placement mapping table consist of a category label, a sorting station grid number, and a discharge station pallet station number. The sorting station grid number corresponds to the grid structure of the sorting station, and the discharge station pallet station number corresponds to the placement position of the pallet carrier at the discharge station.

[0101] The category-based mapping table assigns a unique inspection and sorting station grid number and a unique unloading station pallet station number to each type of hardware in the sorting and classification set. The center distance between the inspection and sorting station grid numbers is set to be no less than 150mm.

[0102] The visual recognition module outputs category labels and category confidence scores based on the 3D imaging results from the 3D camera. The electrical control system receives the category labels and category confidence scores and retrieves the category-position mapping table. The electrical control system generates the target inspection and sorting station grid number and the target material discharge station pallet station number and sends them to the robot body.

[0103] Set a category confidence threshold, which is not less than 0.92. When the electrical control system determines that the category confidence is less than 0.92, it outputs an alarm signal and triggers the turnover box to be transferred to the offline manual processing temporary storage position. The electrical control system maintains the robot body's grasping action in the release and closing state until the offline manual processing temporary storage position returns to the graspable parking posture.

[0104] Step S500.2: Perform customized fixture gripping, placement acceptance and anomaly isolation.

[0105] The robot performs customized gripping. It is equipped with a special hardware fixture and has adjustable mechanical jaws and contoured contact surfaces. The opening stroke of the adjustable mechanical jaws is set from 20mm to 160mm. The contoured contact surfaces are used to fit the clamping features of tension clamps NLD-4, NLD-3, NLD-2, bowl head hangers W-7B and WS-10, U-shaped hanging rings U-25 and U-shaped hanging rings U-7, wedge clamps NX-2, UT clamps NUT-2, and Z-shaped hanging rings Z-7. The special hardware fixture adopts a high-strength alloy structure and outputs the measured clamping force value. The clamping force range corresponding to the measured clamping force value is set from 120N to 450N.

[0106] The robot body performs magnetic suction-enhanced fault-tolerant gripping. During the gripping actions of ball-head ring QP-7, ball-head ring QP-10 and extension ring PH-10, the robot body is equipped with magnetic chucks with a diameter of 80mm and picks up the flat surface. The magnetic chuck adsorption and holding time is set to be no less than 0.30s. After the magnetic chuck adsorption and holding time is met, the robot body performs the transportation action and the placement action.

[0107] During the placement acceptance process, the electrical control system uses a placement acceptance formula to determine the consistency between the placement results at the sorting station and the pallet station at the discharge station. Specifically: In the formula: It is the consistency value of the placement and acceptance. It is the category confidence level. It is the deviation distance of the landing position. The position deviation normalization parameter is set to 5 mm. It is the angle of deviation in the landing posture. It is the attitude deviation normalization parameter and is set to 3^\circ. It is the clamping state factor; the clamping state signal is when it is locked. When the clamp locking status signal is not locked .

[0108] Set the placement acceptance threshold; the placement acceptance threshold is set to... Electrical control system judgment The electrical control system determines whether to release the palletized handover process at the material unloading station. When the abnormality of the inspection and sorting station is detected, an alarm signal is output. After the abnormality of the inspection and sorting station is detected, the turnover box is transferred to the offline manual processing temporary storage position to form an abnormal closed link.

[0109] In some specific embodiments, step S600 specifically includes: Step S600.1: Set the docking rules and pallet guiding correction structure for the unloading station-automatic guided transport vehicle, and configure the docking positioning deviation measurement and positioning correction closed-loop release judgment.

[0110] An automated guided vehicle (AGV) is introduced, which carries the pallet carrier and performs palletized handover with the unloading station. The unloading station is equipped with a pallet docking bracket, which receives the pallet carrier delivered by the AGV and forms a stable positioning reference.

[0111] The docking rules between the unloading station and the automated guided vehicle (AGV) are set. The AGV pushes the pallet carrier to the guide entrance position of the pallet docking bracket. The repeatability of the AGV is set to ±10mm, and the repeatability angle deviation is set to ±1°. The pallet docking bracket is equipped with a rear guard and guide wheels. The rear guard is used to limit the final placement depth of the pallet carrier. The guide wheels are set on the guide surfaces on both sides of the pallet docking bracket and form rolling contact guidance with the sides of the pallet carrier.

[0112] The diameter of the guide wheel is set to 60mm to 90mm, and the reserved guide gap between the guide wheel and the side of the pallet carrier is set to 2mm to 5mm. When the pallet carrier enters the pallet docking bracket, it completes posture convergence under the constraint of the guide wheel, reducing the secondary sorting deviation introduced by palletized handover.

[0113] A docking positioning detection sensor group is introduced and arranged at the unloading station facing the guide entrance area of ​​the pallet docking bracket. The docking positioning detection sensor group outputs the docking position deviation distance and docking angle deviation. The docking position deviation distance is defined as the lateral offset distance between the center line of the pallet carrier and the center line of the pallet docking bracket. The docking angle deviation is defined as the angle deviation between the long side direction of the pallet carrier and the guide direction of the pallet docking bracket.

[0114] Set the docking deviation correction and capture threshold. The docking position deviation distance capture threshold is set to 30mm, and the docking angle deviation capture threshold is set to 3°. The electrical control system receives the docking position deviation distance and docking angle deviation and determines that the correction capture threshold is met. If the correction capture threshold is met, the guide correction wheel is triggered to perform passive correction guidance and the automatic guided transport vehicle is triggered to perform low-speed pushing and positioning action. The low-speed pushing and positioning speed is set to 0.15m / s to 0.30m / s.

[0115] The docking compliance calculation is set, and the electrical control system determines the palletized handover release based on the docking compliance formula, specifically as follows: In the formula: It's about compliance with regulations. It is the deviation distance of the docking position. The position deviation normalization parameter is set to 10mm. It's a deviation in the docking angle. It is the angle deviation normalization parameter and is set to 1°.

[0116] Set the docking release threshold; the docking release threshold is set to... Electrical control system judgment The system outputs a palletized handover release signal and confirms the handover of the pallet carrier. The electrical control system then makes a determination. The system outputs an alarm signal and triggers the automatic guided transport vehicle to exit the docking position and re-dock. The maximum number of re-dock attempts is set to 2. The electrical control system determines that the number of re-dock attempts has reached 2 and maintains this status. When the system is in operation, manual processing is triggered to temporarily store the traffic in the distribution path.

[0117] Step S600.2: Configure the safety light curtain emergency stop link and abnormal recovery connection process.

[0118] A safety light curtain is introduced and positioned at the perimeter of the working area of ​​the hardware sorting robot arm, forming a safety interlock input. A robot control cabinet and an electrical control system control cabinet are also introduced. The robot control cabinet drives the robot body, while the electrical control system control cabinet executes control of the conveyor section, the inspection and sorting station, and the unloading station. The safety light curtain is connected to the emergency stop link between the robot control cabinet and the electrical control system control cabinet, forming a safety interlock closed loop. The response time from the safety light curtain triggering the emergency stop link action is set to no more than 50ms, and the stopping time from the emergency stop link action to the robot body stopping is set to no more than 0.50s.

[0119] On-site usage constraints are set: the noise level of the hardware sorting robot arm is set to less than 75dB, the protection level of the hardware sorting robot arm is set to IP65, and the electrical control system maintains the compliance of the hardware sorting robot arm's operation based on the noise monitoring value and the protection level setting value.

[0120] An abnormal interlocking handling process is set up. After the safety light curtain trigger signal, the alarm signal triggered by the cycle time compliance being less than the cycle time release threshold, the alarm signal triggered by the category confidence being less than the category confidence threshold, and the alarm signal triggered by the placement acceptance consistency value being less than the placement acceptance threshold enter the electrical control system, the electrical control system outputs that the conveyor line suspends control actions and keeps the robot body's grasping action in the release closed state. The electrical control system transfers the turnover box to the offline manual processing temporary storage position and maintains the offline manual processing temporary storage position in an isolated state.

[0121] After the manual processing temporary storage position returns to the gripping and parking posture, the electrical control system releases the suspension control action of the conveyor line and resumes the robot's gripping action release state. The sorting accuracy setting value is not less than 99% and the single cycle action time threshold of 20s remains effective.

[0122] An automatic sorting system for power fittings includes the following modules: The feeding module is used to configure the bag-opening and box-feeding station, configure the conveyor section consisting of telescopic belts and belt conveyors, and set the protection structure and operation status acquisition mechanism of the front-end conveyor section.

[0123] The sorting execution module is used to configure the shuttle garage front area and hardware sorting robotic arm, configure the clamp quick change device and clamp system, set the clamp matching judgment formula and clamp switching link, and set the clamp size threshold and sorting operation indicators.

[0124] The vision grasping module is used to configure the 3D imaging unit of the vision recognition module and the grasping operation support structure, set the candidate grasping pose set judgment and offline manual processing temporary storage position diversion mechanism, set the magnetic attraction enhanced fault-tolerant grasping path and clamping grasping path, set the anti-snagging grasping feasibility formula and component material rules.

[0125] The cycle time coordination module is used to configure the coordinated layout of the offline conveyor line, inspection and sorting station, unloading station and offline manual processing temporary storage station, set the single cycle time constraint of the hardware sorting robot arm and the clamp action cycle time parameters, and set the cycle time compliance formula and cycle time release threshold.

[0126] The sorting and placement module is used to establish sorting categories and category-placement mapping tables, perform category label release judgment and target placement selection, and perform customized fixture gripping, placement acceptance and anomaly isolation.

[0127] The material discharge interlock module is used to set the docking rules between the material discharge station and the automatic guided transport vehicle, as well as the pallet guiding and correction structure. It also configures the docking positioning deviation measurement and positioning correction closed-loop release judgment, and the safety light curtain emergency stop link and abnormal recovery online process.

[0128] In practical application, the above-mentioned material feeding process uses cartons, woven bags, and turnover boxes as the feeding carriers. The bag / box unpacking and feeding station completes the pre-feeding alignment. The feeding guide and limiting structure is aligned with the center line of the upper conveyor section. The upper conveyor section consists of a telescopic belt and a belt conveyor. The telescopic belt has a maximum retracted length ≤5000mm, a maximum extended length ≥11000mm, a unit load ≥60kg / m, and an adjustable height structure. Protective baffles are installed in the movement area of ​​the telescopic mechanism. Protective railings and protective covers are installed around the conveyor belt and rollers. The height of the protective railings is ≥1.2m, and the structural gap is ≤8mm. Material detection sensors, telescopic position sensors, and deviation sensors output the operating status, and the electrical control system triggers the protective control action of the conveyor section.

[0129] The shuttle garage's front area is equipped with a hardware sorting robotic arm. This arm consists of a vision recognition module, a quick-change fixture device, and the robot itself. The quick-change fixture device uses a quick-change master-slave disk and standardized modules, supporting a load of 350kg, 219 input / output points, 4 servo groups, and 40 pneumatic paths. The fixture system includes dedicated hardware single-piece fixtures, carton suction cup fixtures, turnover box fixtures, and burlap sack fixtures. The fixtures have a rated load of ≤50kg, with a carton size threshold of ≤600×500×500mm, a turnover box size threshold of ≤600×400×400mm, and a woven bag size threshold of ≤600×400×300mm. The sorting accuracy is ≥99%, and the sorting efficiency is 5 pieces / min and 5 boxes / min.

[0130] The visual recognition module is equipped with a 3D camera to perform three-dimensional imaging of the power fittings at the feeding position and output a set of candidate gripping poses. When the set of candidate gripping poses is empty, an alarm signal is output and the turnover box is transferred to the offline manual processing temporary storage position. The magnetic suction enhanced fault-tolerant gripping path adopts an 80mm diameter magnetic chuck, and the attitude deviation angle threshold is set to 15°. The gripping path adopts a pneumatic parallel gripper to form a dual-channel gripping path. The feasibility judgment of anti-snagging gripping introduces an attitude normalization parameter of 10° and a gap normalization parameter of 6mm. The wedge-shaped wire clamp NX-2 and the UT-type wire clamp NUT-2 implement the component material separation rules and meet the component spacing ≥50mm. The tension wire clamps NLD-2, NLD-3, and NLD-4 trigger high-snagging risk diversion.

[0131] The offline side is constructed with a continuous layout of offline conveyor line, inspection and sorting station, and unloading station, and an offline manual processing temporary storage position is set to form an abnormal closed loop. The inspection and sorting station performs sampling inspection positioning and abnormal isolation. The sampling inspection positioning trigger ratio is set to 5%. The unloading station performs classified unloading and pallet handover. The pallet carrier's single pallet carrying capacity is set to 20 pieces. The cycle time constraint sets the single cycle action time threshold of the hardware sorting robot arm to 20s, the lifting and adsorption time threshold to 2.5s, the robot body linear speed to 2m / s, the speed coefficient to 90%, the single cycle action time threshold of the material basket gripper to 12s, and the 3D camera's photography action and handling action to be carried out in parallel, with a maximum occupation time of 0.20s and not occupying the single cycle action time threshold.

[0132] The sorting and classification set is set to 13 categories of hardware, and a category-position mapping table is established. Each category is assigned a sorting station grid number and a pallet station number. The grid center distance is set to ≥150mm. The visual recognition module outputs category labels and category confidence scores. The category confidence score threshold is set to ≥0.92. The dedicated hardware fixture is equipped with adjustable mechanical grippers with an opening stroke of 20mm to 160mm, a clamping force of 120N to 450N, and a magnetic chuck adsorption holding time of ≥0.30s. The placement acceptance is based on a position deviation of 5mm and an attitude deviation of 3° as control benchmarks, and the consistency is judged by the fixture locking status signal. If the status is not met, the sorting and classification station is isolated and an alarm signal is output.

[0133] The unloading station and the automated guided vehicle (AGV) perform pallet handover. The AGV's repeatability is set to ±10mm, and the repeatability angle deviation is set to ±1°. The pallet docking bracket is equipped with a rear guard and guide wheels with a diameter of 60-90mm and a reserved guide gap of 2-5mm. The docking deviation correction capture threshold is set to a position deviation of 30mm and an angle deviation of 3°. The low-speed push-in speed is 0.15-0.30m / s, and the maximum number of re-dockings is 2. The safety light curtain is connected to the emergency stop link, with a response time ≤50ms, a stop time ≤0.50s, noise <75dB, and a protection level of IP65. Abnormal signals trigger the suspension of the conveyor line and the diversion of the temporary storage position. After the handling is completed, the connection is restored and the sorting accuracy is maintained at ≥99% and the single cycle action time threshold is 20s.

Claims

1. An automatic sorting method for power fittings, characterized in that, Includes the following steps: S100, configured with bag opening and box feeding box online station, configured with online conveyor section composed of telescopic belt and belt line, set front-end conveyor section protection structure and operation status acquisition mechanism. S200, equipped with a shuttle garage front area and hardware sorting robotic arm, equipped with a quick-change device and a fixture system, set a fixture matching judgment formula and fixture switching link, set fixture size threshold and sorting operation indicators; S300, configured with a visual recognition module, a three-dimensional imaging unit and a gripping operation support structure, sets a candidate gripping pose set judgment and a temporary storage mechanism for offline manual processing, sets a magnetically enhanced fault-tolerant gripping path and a clamping gripping path, and sets an anti-snagging gripping feasibility formula and component material rules. S400, configured with offline conveyor line, inspection and sorting station, material discharge station and offline manual processing temporary storage station in a coordinated layout, set single cycle cycle constraints of hardware sorting robot arm and clamp action cycle parameters, set cycle compliance formula and cycle release threshold. S500: Establish sorting and classification sets and category-placement mapping tables, perform category label release judgment and target placement selection, and perform customized fixture gripping, placement acceptance and anomaly isolation. S600: Set the docking rules and pallet guiding correction structure for the unloading station-automatic guided transport vehicle; configure docking positioning deviation measurement and positioning correction closed-loop release judgment; configure safety light curtain emergency stop link and abnormal recovery online process.

2. The automatic sorting method for power fittings according to claim 1, characterized in that, S100 specifically includes: S100.1, Configure bag opening and box feeding box online workstations, and configure online conveyor section composed of telescopic belt and belt line; Configure a bag / box unpacking and feeding box online station. The bag / box unpacking and feeding box online station is used to receive three types of feeding carriers: cartons, woven bags and turnover boxes, and to align the shape and posture of cartons, woven bags and turnover boxes before they are put on the line. The system is configured with an online conveyor section, which consists of a telescopic belt and a conveyor belt. The telescopic belt is located on the discharge side of the bag / box feeding station, and the conveyor belt is located on the receiving side of the telescopic belt. S100.1, Set the protection structure and operation status acquisition mechanism for the front-end conveyor section; Set up a protective structure for the front conveyor section, install guardrails around the conveyor belt and rollers, install a protective cover on the outside of the guardrails, set the height of the guardrails to be no less than 1.2m, set the structural gap of the guardrails to be no more than 8mm, install a protective baffle in the movement area of ​​the telescopic mechanism, and cover the extension stroke area and retraction stroke area of ​​the telescopic mechanism. An operational status acquisition mechanism is set up, with material detection sensors, telescopic position sensors, and belt misalignment sensors installed in the front-end conveyor section. The material detection sensors output the arrival signal of cartons, woven bags, and turnover boxes entering the telescopic belt, the telescopic position sensors output the extension length status of the telescopic belt, and the belt misalignment sensors output the belt misalignment status.

3. The automatic sorting method for power fittings according to claim 1, characterized in that, S200 specifically includes: S200.1 Configure the shuttle garage front area and hardware sorting robotic arm, configure the clamp quick change device and clamp system, and set the clamp matching judgment formula and clamp switching link; The shuttle garage front area is configured with a hardware sorting and feeding station. The hardware sorting and feeding station is connected to the online conveyor section. After the cardboard boxes, woven bags and turnover boxes enter the hardware sorting and feeding station, they are kept in a grabbable and parking posture. A hardware sorting robot arm is configured, which includes a vision recognition module, a clamp quick-change device and a robot body. The vision recognition module outputs the target positioning result and the target posture result of the power hardware. The clamp quick-change device carries the clamp system and completes the clamp switching. The robot body performs grasping, carrying and placing actions based on the target positioning result and the target posture result of the power hardware, forming an automatic sorting execution unit. The fixture quick-change device includes a fixture quick-change master and slave disk and a standardization module. The fixture quick-change master and slave disk supports a load setting of 350kg, the standardization module supports an input / output point setting of 219 points, the standardization module supports a servo group setting of 4 groups, and the standardization module supports an air path setting of 40 paths. A clamping system is set up, which includes special hardware single clamps, cardboard box suction cup clamps, turnover box special clamps and burlap sack special clamps. The special hardware single clamps clamp the power hardware single clamps, the cardboard box suction cup clamps the cardboard boxes, the turnover box special clamps clamp the turnover boxes, and the burlap sack special clamps clamp the woven bags. Set a fixture matching determination formula. The fixture matching determination formula is used to complete the fixture selection and release among special hardware single fixtures, carton suction cup fixtures, turnover box special fixtures and burlap bag special fixtures. The fixture selection and release triggers the fixture quick change device to complete the fixture switching and output the fixture locking status signal. Set up a fixture switching link, which includes fixture return to zero position, fixture docking position, fixture locking confirmation and fixture disengagement confirmation. The electrical control system receives the fixture locking status signal and uses the fixture locking status signal as the condition for fixture switching to be completed. After the fixture switching is completed, the electrical control system sends a grasping action control command to the robot body. S200.2, Set fixture size thresholds and sorting operation indicators; Set clamp size thresholds: the cardboard box suction cup clamp is set to a cardboard box size threshold of no more than 600×500×500mm, the turnover box clamp is set to a turnover box size threshold of no more than 600×400×400mm, and the burlap sack clamp is set to a woven bag size threshold of no more than 600×400×300mm. Set sorting operation indicators: sorting accuracy is set to no less than 99%, sorting efficiency is set to 5 items / min and 5 boxes / min. The electrical control system records the sorting accuracy statistics and sorting efficiency statistics. The sorting accuracy statistics are used to constrain the output stability of the vision recognition module, and the sorting efficiency statistics are used to constrain the switching cycle stability of the quick-change fixture.

4. The automatic sorting method for power fittings according to claim 1, characterized in that, The S300 specifically includes: S300.1, Configure the visual recognition module, three-dimensional imaging unit and grasping operation support structure, set the candidate grasping pose set judgment and offline manual processing temporary position diversion mechanism, set the magnetic attraction enhanced fault-tolerant grasping path and clamping grasping path; The visual recognition module is equipped with a 3D imaging unit. The 3D imaging unit uses a 3D camera to perform 3D imaging of the power fittings in the material feeding position of the fitting sorting operation. Based on the 3D imaging results, the visual recognition module outputs the power fitting target positioning result, the power fitting target posture result and the candidate grasping posture set. Configure a robot tooling rack, which is designed to hold four types of tooling. The four types of tooling are used to support the order of use of special hardware single clamps, cardboard box suction cup clamps, turnover box special clamps and burlap sack special clamps. A gripper storage platform is configured to store special hardware single clamps, cardboard box suction cup clamps, turnover box special clamps and burlap bag special clamps at fixed points. The hardware sorting robot arm completes the orderly storage and retrieval of clamps based on the gripper storage platform. A candidate grasping pose set determination mechanism is set up. The electrical control system receives the candidate grasping pose set. When the electrical control system determines that the candidate grasping pose set is empty, it outputs an alarm signal. The alarm signal triggers the turnover box to be transferred to the offline manual processing temporary storage position. A magnetically enhanced fault-tolerant gripping path is set up. The magnetically enhanced fault-tolerant gripping path uses a magnetic chuck with a diameter of 80mm as the end gripping component. The magnetic chuck performs a suction action on the flat surface of the power fitting. The magnetically enhanced fault-tolerant gripping path is suitable for ball head hanging rings QP-7, ball head hanging rings QP-10, cup head hanging plates W-7B, cup head hanging plates WS-10, U-shaped hanging rings U-7, extension rings PH-10 and Z-7. The magnetic attraction-enhanced fault-tolerant grasping path is set with a posture deviation angle threshold of 15°. When the posture deviation angle exceeds 15°, the magnetic attraction-enhanced fault-tolerant grasping path is blocked and allowed to proceed, and the process is switched to the candidate grasping pose set for regeneration. A clamping and gripping path is set. The clamping and gripping path uses pneumatic parallel grippers as end gripping components. The pneumatic parallel grippers grip the clamping feature parts of the power fittings. The clamping and gripping path is used to support the gripping of power fittings other than the magnetic attraction enhanced fault tolerance gripping path. The magnetic attraction enhanced fault tolerance gripping path and the clamping and gripping path form a dual-channel gripping path. S300.2, Set the formula for the feasibility of anti-snagging and grabbing and the rules for component materials; The feasibility calculation of anti-snagging grasping is set, and the electrical control system performs grasping posture release judgment on the candidate grasping posture set based on the anti-snagging grasping feasibility formula; Set the capture pose release threshold; the capture pose release threshold is set to... Electrical control system judgment The system sends a grasping action control command to the robot body, and the electrical control system determines... The system outputs an alarm signal and triggers the turnover box to be transferred to the offline manual processing temporary storage position. Set rules for component separation. Wedge clamp NX-2 and UT clamp NUT-2 are defined as component separation materials. These materials are stored and handled separately. The spacing between separately stored components is set to be no less than 50mm. Separate handling is performed within the same turnover box, releasing components sequentially according to their serial numbers to reduce the probability of handling failure due to separation. Tension clamps NLD-2, NLD-3, and NLD-4 are defined as high-risk materials for entanglement. High-risk materials are handled in... The process will directly trigger the offline manual processing temporary storage route.

5. The automatic sorting method for power fittings according to claim 1, characterized in that, The S400 specifically includes: S400.1 Configure the offline conveyor line, inspection and sorting station, material discharge station and offline manual processing temporary storage station in a coordinated layout, and set the single cycle cycle constraint of the hardware sorting robot arm and the clamp action cycle parameters. A collaborative layout for the offline production line is constructed, consisting of an offline conveyor line, an inspection and sorting station, and an unloading station. The offline conveyor line connects with the landing area of ​​the hardware sorting robot arm. The offline conveyor line undertakes the placement action of the robot body and forms a continuous conveying path. The inspection and sorting station is located in the middle of the off-line conveyor. The inspection and sorting station is used to perform spot inspection positioning and abnormal isolation. The trigger ratio for spot inspection positioning is set to 5%. The trigger conditions for abnormal isolation include an alarm signal triggered when the candidate grasping pose set is empty and an alarm signal triggered when the anti-clamping grasping feasibility is less than the grasping pose release threshold. Configure a temporary storage location for offline manual processing. The temporary storage location for offline manual processing is located in the front area of ​​the shuttle garage and is isolated from the material feeding location of the hardware sorting operation. After the alarm signal triggers the turnover box to be transferred to the temporary storage location for offline manual processing, the electrical control system maintains the robot body's gripping action in the release and closing state until the temporary storage location for offline manual processing completes the diversion and returns to the gripping and parking posture. A single-cycle action time threshold is set for the hardware sorting robot arm, which is set to 20s. The electrical control system performs cycle constraint control on the robot body's gripping, transporting, and positioning actions based on the single-cycle action time threshold. A lifting and adsorption time threshold is set for the carton gripper made of carton suction cup clamp and the bag gripper made of burlap sack special clamp, which is set to 2.5s. The robot body linear speed parameter is set to 2m / s, and the robot body speed coefficient is set to 90%. Under the constraints of the robot body linear speed parameter and the robot body speed coefficient, the carton gripper and bag gripper form a work cycle with a single cycle time of about 14s. A parallel mechanism for 3D camera photography is set up, where the 3D camera photography action and the robot's handling action are kept in parallel. The maximum time occupied by the 3D camera photography action is set to 0.20s, and the 3D camera photography action does not occupy the single loop action time threshold. S400.2, Set the rhythm compliance formula and rhythm release threshold; The cycle time compliance calculation is set, and the electrical control system determines the cycle time release of the hardware sorting robot arm based on the cycle time compliance formula, specifically as follows: In the formula: It's about rhythm compliance. The single-loop action time threshold is set to 20 seconds. This is the actual measured single-cycle action time of the hardware sorting robot arm; Set the timer release threshold; the timer release threshold is set to... Electrical control system judgment The electrical control system determines that the robot's grasping action is in the open state. It outputs an alarm signal and transfers the turnover box to the offline manual processing temporary storage position.

6. The automatic sorting method for power fittings according to claim 1, characterized in that, The S500 specifically includes: S500.1 Establish a sorting classification set and category location mapping table, and perform category label release judgment and target location selection; Establish a sorting classification set, which includes tension clamp NLD-4, tension clamp NLD-3, tension clamp NLD-2, bowl head hanging plate W-7B, bowl head hanging plate WS-10, ball head hanging ring QP-7, ball head hanging ring QP-10, U-shaped hanging ring U-25, U-shaped hanging ring U-7, extension ring PH-10, wedge clamp NX-2, UT type clamp NUT-2, and Z type hanging ring Z-7; Establish a category placement mapping table, which is stored by the electrical control system. The entries in the category placement mapping table consist of category labels, inspection and sorting station grid numbers, and discharge station pallet station numbers. The inspection and sorting station grid number corresponds to the grid structure of the inspection and sorting station, and the discharge station pallet station number corresponds to the placement position of the pallet carrier at the discharge station. The visual recognition module outputs category labels and category confidence scores based on the three-dimensional imaging results of the 3D camera. The electrical control system receives the category labels and category confidence scores and retrieves the category-position mapping table. The electrical control system generates the target inspection and sorting station grid number and the target material discharge station pallet station number and sends them to the robot body. Set a category confidence threshold, which is not less than 0.

92. When the electrical control system determines that the category confidence is less than 0.92, it outputs an alarm signal and triggers the turnover box to be transferred to the offline manual processing temporary storage position. The electrical control system maintains the robot body's grasping action in the release and closing state until the offline manual processing temporary storage position returns to the graspable parking posture. S500.2, Implement customized fixture gripping, placement acceptance, and anomaly isolation; The robot body is equipped with a special hardware fixture for customized gripping. The special hardware fixture is equipped with adjustable mechanical jaws and contoured contact surfaces. The opening stroke of the adjustable mechanical jaws is set from 20mm to 160mm. The contoured contact surfaces are used to fit the clamping features of tension clamps NLD-4, NLD-3, NLD-2, bowl head hangers W-7B, WS-10, U-shaped hanging rings U-25, U-shaped hanging rings U-7, wedge clamps NX-2, UT clamps NUT-2, and Z-shaped hanging rings Z-7. The special hardware fixture adopts a high-strength alloy structure and outputs the measured clamping force value. The clamping force range corresponding to the measured clamping force value is set from 120N to 450N. To perform magnetically enhanced fault-tolerant gripping, the robot body is equipped with an 80mm diameter magnetic chuck during the gripping action of the ball-head hanging ring QP-7, ball-head hanging ring QP-10, and extension ring PH-10, and the magnetic chuck is held in place on a flat surface. The magnetic chuck holding time is set to be no less than 0.30s. After the magnetic chuck holding time is met, the robot body performs the transport and placement actions. During the placement acceptance process, the electrical control system uses the placement acceptance formula to determine the consistency between the placement results of the sorting station grid and the placement results of the unloading station pallet station. Set the placement acceptance threshold; the placement acceptance threshold is set to... Electrical control system judgment The electrical control system determines whether to release the palletized handover process at the material unloading station. When the abnormality of the inspection and sorting station is detected, an alarm signal is output. After the abnormality of the inspection and sorting station is detected, the turnover box is transferred to the offline manual processing temporary storage position to form an abnormal closed link.

7. The automatic sorting method for power fittings according to claim 1, characterized in that, The S600 specifically includes: S600.1, Set the docking rules and pallet guiding correction structure for the unloading station-automatic guided transport vehicle, and configure docking positioning deviation measurement and positioning correction closed-loop release judgment; An automated guided vehicle (AGV) is introduced. The AGV carries the pallet carrier and performs palletized handover with the unloading station. The unloading station is equipped with a pallet docking bracket, which receives the pallet carrier delivered by the AGV and forms a stable positioning reference. The docking rules between the unloading station and the automated guided vehicle (AGV) are set. The AGV pushes the pallet carrier to the guide entrance position of the pallet docking bracket. The repeatability of the AGV is set to ±10mm, and the repeatability angle deviation is set to ±1°. The pallet docking bracket is equipped with a rear guard and guide wheels. The rear guard is used to limit the final placement depth of the pallet carrier. The guide wheels are set on the guide surfaces on both sides of the pallet docking bracket and form rolling contact guidance with the sides of the pallet carrier. A docking positioning detection sensor group is introduced and arranged at the unloading station facing the guide entrance area of ​​the pallet docking bracket. The docking positioning detection sensor group outputs the docking position deviation distance and docking angle deviation. The docking position deviation distance is defined as the lateral offset distance between the center line of the pallet carrier and the center line of the pallet docking bracket. The docking angle deviation is defined as the angle deviation between the long side direction of the pallet carrier and the guide direction of the pallet docking bracket. Set the docking deviation correction and capture threshold. The docking position deviation distance capture threshold is set to 30mm, and the docking angle deviation capture threshold is set to 3°. The electrical control system receives the docking position deviation distance and docking angle deviation and determines that the correction capture threshold is met. If the correction capture threshold is met, the guide correction wheel is triggered to perform passive correction guidance and the automatic guided transport vehicle is triggered to perform low-speed pushing and positioning action. The low-speed pushing and positioning speed is set to 0.15m / s to 0.30m / s. The docking compliance calculation is set, and the electrical control system determines the palletized handover release based on the docking compliance formula; Set the docking release threshold; the docking release threshold is set to... Electrical control system judgment The system outputs a palletized handover release signal and confirms the handover of the pallet carrier. The electrical control system then makes a determination. The system outputs an alarm signal and triggers the automatic guided transport vehicle to exit the docking position and re-dock. The maximum number of re-dock attempts is set to 2. The electrical control system determines that the number of re-dock attempts has reached 2 and maintains this status. The temporary storage location for traffic diversion is triggered when the system is offline and manually processed. S600.2, Configure the safety light curtain emergency stop link and abnormal recovery connection process; A safety light curtain is introduced and placed at the perimeter of the working area of ​​the hardware sorting robot arm to form a safety interlock input. The robot cabinet and the electrical control system cabinet are introduced. The robot cabinet is used to drive the robot body, and the electrical control system cabinet is used to execute the control of the conveyor section, the control of the inspection and sorting table, and the control of the unloading station. The safety light curtain is connected to the emergency stop link between the robot cabinet and the electrical control system cabinet to form a safety interlock closed loop. The response time from the safety light curtain triggering the emergency stop link action is set to no more than 50ms, and the stopping time from the emergency stop link action to the robot body stopping is set to no more than 0.50s. Set on-site usage constraints: the noise level of the hardware sorting robot arm is set to be less than 75dB, the protection level of the hardware sorting robot arm is set to IP65, and the electrical control system maintains the compliance of the hardware sorting robot arm's operating status based on the noise monitoring value and the protection level setting value. An abnormal interlocking handling process is set up. After the safety light curtain trigger signal, the alarm signal triggered by the cycle time compliance being less than the cycle time release threshold, the alarm signal triggered by the category confidence being less than the category confidence threshold, and the alarm signal triggered by the placement acceptance consistency value being less than the placement acceptance threshold enter the electrical control system, the electrical control system outputs that the conveyor line suspends control actions and keeps the robot body's grasping action in the release closed state. The electrical control system transfers the turnover box to the offline manual processing temporary storage position and maintains the offline manual processing temporary storage position in an isolated state.

8. An automatic sorting system for power fittings, implementing a three-dimensional warehouse scheduling method based on a four-way shuttle as described in any one of claims 1-7, characterized in that, Includes the following modules: The feeding module is used to configure the bag-opening and box-feeding box loading stations, configure the conveyor section consisting of telescopic belts and belt conveyors, and set the front-end conveyor section protection structure and operation status acquisition mechanism. The sorting execution module is used to configure the shuttle garage front area and hardware sorting robotic arm, configure the quick-change device and fixture system, set the fixture matching judgment formula and fixture switching link, and set the fixture size threshold and sorting operation indicators. The vision grasping module is used to configure the 3D imaging unit of the vision recognition module and the grasping operation support structure, set the candidate grasping pose set judgment and offline manual processing temporary storage position diversion mechanism, set the magnetic attraction enhanced fault-tolerant grasping path and clamping grasping path, set the anti-snagging grasping feasibility formula and component material rules. The cycle time coordination module is used to configure the coordinated layout of the offline conveyor line, the inspection and sorting station, the material discharge station and the offline manual processing temporary storage station, set the single cycle cycle time constraint of the hardware sorting robot arm and the clamp action cycle time parameters, and set the cycle time compliance formula and cycle time release threshold. The sorting and placement module is used to establish sorting categories and category-placement mapping tables, perform category label release judgment and target placement selection, and perform customized fixture gripping, placement acceptance and anomaly isolation. The material discharge interlock module is used to set the docking rules between the material discharge station and the automatic guided transport vehicle, as well as the pallet guiding and correction structure. It also configures the docking positioning deviation measurement and positioning correction closed-loop release judgment, and the safety light curtain emergency stop link and abnormal recovery online process.

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