A method and system for random packaging of equal quantities of products based on virtual workstation mapping

Abstract

This invention relates to the field of product packaging technology and discloses a method for random packaging of equal-quantity products based on virtual workstation mapping, comprising the following steps: S1, generating multiple non-repeating random combination sequences according to the capacity N of the product packaging unit; S2, creating virtual workstations that move synchronously with the physical packaging units in the virtual space of the packaging conveyor line; S3, sequentially setting at least N work areas along the packaging conveyor line, each work area being configured with a robotic arm; configuring a control instruction set for each virtual workstation; S4, each time a virtual workstation passes through a work area, the robotic arm of that work area performs a product gripping and placing operation, placing the product on the fixed physical position of the physical packaging unit corresponding to that coordinate; S5, after a virtual workstation has traversed all work areas, it enters the packaging workstation for sealing. This invention has the beneficial effects of flexible scheduling and more uniform random product distribution.

Description

Technical Field

[0001] This invention relates to the field of product packaging technology, and in particular to a method and system for random packaging of equal quantities of products based on virtual workstation mapping. Background Technology

[0002] With the rapid development of intelligent manufacturing, modern production environments face increasingly complex and dynamic challenges. Especially in ever-changing production tasks, how to efficiently schedule the coordination between robots (or robotic arms) and workstations has become a crucial issue for improving production efficiency and flexibility. Traditional production line control methods largely rely on static planning, which struggles to cope with frequently changing production demands and uncertainties within the system. For example, on a continuous packaging production line, fixed product capacities (small boxes) need to be packaged to form packaging units (medium boxes), and finally, these units are boxed (large boxes). Furthermore, it's essential that the order of the small boxes within each medium box is different, a requirement widely applied in blind box production. Current static planning-based robotic arm scheduling methods clearly cannot meet the continuous automated packaging needs of blind box products. Therefore, a more intelligent and dynamic control strategy is needed to achieve adaptive scheduling of production tasks. Summary of the Invention

[0003] In order to solve the above-mentioned problems in the prior art, the present invention provides a method and system for random packaging of equal quantities of products based on virtual workstation mapping, which allows for more flexible scheduling and more stable random product distribution.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: A method for random packaging of equal quantities of products based on virtual workstation mapping includes the following steps: S1. Based on the capacity N of the product packaging unit, generate multiple non-repeating random combination sequences, each of which is bound to a unique sequence identifier. It includes N product placement coordinates that correspond one-to-one with N fixed physical locations within the packaging unit. , ), where m and i are natural numbers; S2. In the virtual space of the packaging conveyor line, create virtual workstations that move synchronously with the physical packaging units. Each virtual workstation is bound to one of the random combination sequences and its sequence identifier. ; S3. At least N work areas are set up sequentially along the packaging conveyor line, and each work area is equipped with a robotic arm; a control instruction set is configured for each virtual workstation, the control instruction set containing N product placement coordinates in a random combination sequence bound to it, and the N product placement coordinates are pre-assigned to the at least N robotic arms respectively, so that when the virtual workstation reaches the work area corresponding to a certain robotic arm, the robotic arm executes the pre-assigned product placement coordinates; S4. The virtual workstation moves along the packaging conveyor line and passes through each of the work areas in sequence. Each time it passes through a work area, the robotic arm of that work area performs a product gripping and placing operation according to the product placement coordinates pre-assigned to the current virtual workstation, placing the product on the fixed physical position of the physical packaging unit corresponding to the coordinates. S5. After a virtual workstation has traversed all work areas, its corresponding physical packaging unit has placed N products and then entered the packaging workstation for sealing.

[0005] Preferably, the virtual workstations are distributed at equal intervals in the virtual space of the packaging conveyor line and move in the same direction and at the same speed as the packaging conveyor line.

[0006] Preferably, in step S3, the number of robotic arms Gz is equal to the product capacity N, and each robotic arm is fixed to place one product.

[0007] Preferably, each of the work areas is physically fixed on the packaging conveyor line and has a robotic arm working origin; the robotic arm waits at the working origin and grabs the product, when a serial number is bound. When the virtual workstation arrives, the placement action is performed according to the pre-assigned product placement coordinates.

[0008] As a preferred option, the product also includes a step of randomly adding a previously hidden product to the product packaging unit, specifically: S01. Define a virtual workstation group consisting of M consecutive virtual workstations, where M≥2; S02. For each virtual workstation group, randomly select Q fixed physical locations as hidden item delivery locations, where 1≤Q<N; S03. Divide the robotic arms into N regular robotic arms and Q special robotic arms; the regular robotic arms are used to grasp and release regular products, and the special robotic arms are used to grasp and release hidden products. S04. In the control instruction set of step S3, add a hidden item marker to the product placement coordinates of the product selected as the hidden item placement location; S05. In step S4, when the robotic arm performs the placement operation: if the pre-assigned product placement coordinates do not have hidden product markings, the conventional robotic arm performs the conventional product placement; if the pre-assigned product placement coordinates have hidden product markings, the special robotic arm performs the hidden product placement, and the conventional robotic arm remains on standby during the work cycle corresponding to that coordinate.

[0009] As a preferred option, the product also includes a step of adding a rear-mounted hidden product before packaging: after packaging is completed in step S5 and before the packaging station, at least one pre-packaged packaging unit containing the hidden product is mixed and packaged with multiple conventional packaging units produced through steps S1 to S5.

[0010] A random packaging system for equal-quantity products based on virtual workstation mapping, characterized in that it includes: a packaging conveyor line for carrying and conveying physical packaging units; A control server includes a random sequence generation module for performing step S1 as described in claim 1 to generate the random combination sequence; The virtual workstation management module is used to perform step S2 as described in claim 1, to create and manage the virtual workstation, and to generate the control instruction set; At least N robotic arms are sequentially arranged along the packaging conveyor line, with each robotic arm corresponding to a work area; and The motion controller is communicatively connected to the virtual workstation management module, the packaging conveyor line, and each of the robotic arms. It is used to synchronize the movement of the virtual workstation with the movement of the packaging conveyor line, and to command each robotic arm to perform product placement operations in the corresponding work area according to the control instruction set issued by the virtual workstation management module.

[0011] Preferably, the virtual workstation management module is configured to ensure that all virtual workstations maintain equal spacing in the virtual space and move synchronously with the packaging conveyor line.

[0012] Preferably, the system also includes a hidden item management module, which performs steps S01 to S04 as described in claim 5, generates a set of control instructions containing hidden item markers, and coordinates the movements of the conventional robotic arm and the special robotic arm.

[0013] Therefore, the present invention has the following beneficial effects: (1) By pre-generating a random combination sequence without repetition and binding it with the virtual workstation, the uniqueness and randomness of the product arrangement in each packaging unit are fundamentally guaranteed, which perfectly meets the essential needs of products such as "blind boxes"; (2) By pre-allocating a set of control instructions to each virtual workstation and allowing the robotic arm to execute in the corresponding work area, the randomized logic and the timing of mechanical execution are decoupled, so that the high-speed, parallel automated production line can reliably realize complex random arrangement; (3) The "virtual workstation" is a logical carrier, independent of physical hardware, so that when changing the packaging specifications (capacity N) or production rhythm, only the software parameters need to be adjusted, without modifying the production line layout, which greatly improves the adaptability and reconfigurability of the system. Attached Figure Description

[0014] Figure 1 This is a schematic diagram showing the distribution of the packaging conveyor line and robotic arm without the hidden version.

[0015] Figure 2 This is a schematic diagram showing the distribution of the packaging conveyor line with concealed features and the robotic arm.

[0016] Figure 3 This is a schematic diagram of the product distribution within a group of packaging units in virtual workstation 0001 in Example 1.

[0017] Figure 4 This is a schematic diagram showing the missing position of the hidden item in the virtual workstation 0003, which includes the hidden item in Example 2.

[0018] Figure 5 This is a schematic diagram showing the position of the hidden item in the virtual workstation 0003, which includes the hidden item in Example 2, after the hidden item has been placed.

[0019] In the picture: Packaging conveyor line 1, robotic arm 2. Detailed Implementation

[0020] To make the technical problems to be solved, the technical solutions, and the beneficial technical effects of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and several exemplary embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of protection of this invention.

[0021] It should be understood that the terms "first," "second," etc., used herein are for descriptive purposes only and should not be construed as indicating or implying relative importance, nor should they be construed as implicitly specifying the number of technical features indicated. Features specified as "first" or "second" may expressly or implicitly indicate that at least one of those features is included.

[0022] A method for random packaging of equal quantities of products based on virtual workstation mapping includes the following steps: S1. Based on the capacity N of the product packaging unit, generate multiple non-repeating random combination sequences, each of which is bound to a unique sequence identifier. It includes N product placement coordinates that correspond one-to-one with N fixed physical locations within the packaging unit. , S2. In the virtual space of the packaging conveyor line, virtual workstations that move synchronously with the physical packaging units are created, and each virtual workstation is bound to a random combination sequence and its sequence identifier. S3. At least N work areas are sequentially set along the packaging conveyor line, and each work area is equipped with a robotic arm; a control instruction set is configured for each virtual workstation, the control instruction set containing N product placement coordinates in a random combination sequence bound to it, and the N product placement coordinates are pre-assigned to the at least N robotic arms respectively, so that when the virtual workstation reaches the work area corresponding to a certain robotic arm, the robotic arm executes the pre-assigned product placement coordinates; S4. The virtual workstation moves along the packaging conveyor line and passes through each of the work areas sequentially; each time it passes through a work area, the robotic arm of the work area performs a product gripping and placing operation according to the product placement coordinates pre-assigned to the current virtual workstation, placing the product on the fixed physical position of the physical packaging unit corresponding to the coordinate; S5. When a virtual workstation has traversed all work areas, its corresponding physical packaging unit completes the placement of N products, and then enters the packaging workstation for packaging.

[0023] The virtual workstations are evenly spaced within the virtual space of the packaging conveyor line and move in the same direction and at the same speed as the packaging conveyor line. In some embodiments, in step S3, the number of robotic arms Gz is equal to the product capacity N, and each robotic arm is fixedly responsible for placing one product. Each work area has a fixed physical location on the packaging conveyor line and is equipped with a robotic arm work origin; the robotic arm waits at the work origin and grabs the product, when a sequence identifier is bound... When the virtual workstation arrives, the placement action is performed according to the pre-assigned product placement coordinates.

[0024] In some embodiments, the method further includes a step of randomly adding a hidden product to the product packaging unit, specifically: S01, defining a virtual workstation group consisting of M consecutive virtual workstations, where M≥2; S02, for each virtual workstation group, randomly selecting Q fixed physical locations as hidden product placement locations, where 1≤Q<N; S03, dividing the robotic arms into N regular robotic arms and Q special robotic arms; the regular robotic arms are used to pick up and place regular products, and the special robotic arms are used to pick up and place hidden product products; S04, in the control instruction set of step S3, adding a hidden product mark to the product placement coordinates selected as hidden product placement locations; S05, in step S4, when the robotic arm performs the placement operation: if the pre-assigned product placement coordinates do not have a hidden product mark, the regular robotic arm performs regular product placement; if the pre-assigned product placement coordinates have a hidden product mark, the special robotic arm performs hidden product placement, and the regular robotic arm remains on standby during the work cycle corresponding to that coordinate.

[0025] In some embodiments, the method further includes adding a rear-mounted hidden product before product packaging: after packaging is completed in step S5 and before the packaging station, at least one pre-packaged packaging unit containing the hidden product is mixed and packaged with multiple conventional packaging units produced by steps S1 to S5.

[0026] A random packaging system for equal-quantity products based on virtual workstation mapping includes: a packaging conveyor line 1 for carrying and conveying physical packaging units; a control server including a random sequence generation module for executing the random combination sequence generated in step S1; a virtual workstation management module for executing step S2, creating and managing the virtual workstations, and generating the control instruction set; at least N robotic arms 2, sequentially arranged along the packaging conveyor line, each robotic arm corresponding to a work area; and a motion controller, communicatively connected to the virtual workstation management module, the packaging conveyor line, and each robotic arm, for synchronizing the movement of the virtual workstations with the movement of the packaging conveyor line, and directing each robotic arm to perform product placement operations in its corresponding work area according to the control instruction set issued by the virtual workstation management module. The virtual workstation management module is configured to maintain equal spacing between all virtual workstations in virtual space and move synchronously with the packaging conveyor line. It also includes a hidden item management module for executing steps S01 to S04, generating a control instruction set containing hidden item markers, and coordinating the movements of the conventional and special robotic arms.

[0027] Example 1: Random packaging without the hidden version, such as Figure 1 As shown, taking a packaging capacity of N=12 and Gz=12 as an example, that is, each packaging box needs to package 12 different regular products, and the packaging conveyor line is equipped with 12 regular robotic arms. The steps are as follows: Random sequence generation: Control the server's random sequence generation module to generate a sufficient number of non-repeating random combination sequences for this production batch. Each random combination sequence is assigned a unique sequence identifier. (e.g., O001, O002, …), and includes 12 random product placement coordinates ( , )to( , These 12 coordinates correspond one-to-one with 12 fixed positions within the packaging unit.

[0028] Virtual workstation creation and binding: The virtual workstation management module creates virtual workstations in the system's virtual space. Each virtual workstation is associated with the starting position of a packaging unit on the conveyor line and bound to a random sequence generated above (e.g., virtual workstation 1 is bound to O001, virtual workstation 2 is bound to O002, ...). All virtual workstations are set to be equally spaced in the virtual space and "move" in the same direction of motion as the conveyor line.

[0029] Control command pre-assignment: For each virtual workstation (e.g., the virtual workstation bound to O001), the system generates a control command set containing 12 commands, each command containing a product placement coordinate. These 12 commands are pre-assigned sequentially to the 12 robotic arms (G1 to G12) from upstream to downstream, according to the workstation's movement direction. For example, command 1 - coordinate ( , ) is assigned to robotic arm G1, instruction 2 - coordinate ( , ) are assigned to robotic arm G2, and so on.

[0030] Synchronized Motion and Execution: The motion controller drives the packaging conveyor line forward and strictly synchronizes the positions of all virtual workstations in virtual space. The motion controller sends the command coordinates of its pre-assigned bound workstation 0001 to the robotic arm G1. , When the virtual workstation bound to O001 "arrives" at the work area of ​​the robotic arm G1, the robotic arm G1 moves a product A from its work origin (where the robotic arm G1 has pre-grabbed the product and is waiting) to coordinate ( , The corresponding physical location is then used to place product A. Since both the packaging box conveyor line and the virtual workstation move at a constant speed along the X or Y direction, the robotic arm G1 moves from the work origin to the coordinate ( ). , The speed in the X or Y direction needs to be compensated. This is a built-in compensation function of the robotic arm control system, which will not be elaborated upon in this embodiment. Each position of the virtual workstation has fixed position coordinates. The robotic arm G1 receives ( , After that, according to ( , The value of ) is matched with the corresponding position coordinates of the virtual workstation, and product A is placed at that position coordinate of the virtual workstation; the robotic arm G1 places product A accordingly and obtains the signal ( , Robotic arm G2 is positioned to place product B and receives a signal ( , ), and so on.

[0031] The assembly line operation completes packaging: The virtual workstation sequentially passes through work areas G2 to G12. Each robotic arm, at its corresponding moment, receives a unique coordinate instruction pre-assigned to that workstation and performs a placement operation. When the virtual workstation leaves the work area G12, 12 products are placed at each of the 12 coordinate positions on the virtual workstation bound to 0001, and the arrangement order is completely uniquely determined by the sequence O001. Figure 3 The 12 products shown are arranged according to coordinates ( ). , )to( , (See diagram for arrangement). Subsequently, this group of packaging units enters the packaging station for packaging. Simultaneously, subsequent virtual stations (such as the station bound to O002) also sequentially pass through each robotic arm, but execute a completely different set of random coordinate instructions, thus achieving absolute randomness and non-repetition in the product arrangement between boxes.

[0032] Example 2: Includes a hidden, random packaging, such as... Figure 2 As shown, this embodiment adds a pre-positioned hidden product delivery function based on embodiment 1: The product capacity is set to N=12, the virtual workstation group size is M=6, and one hidden product (Q=1) is randomly delivered to each group. The system is configured with 12 regular robotic arms and 1 special robotic arm (a total of 13 arms). The special robotic arm can be set in any fixed work area in the downstream of the production line, for example, it can be set as the 13th work arm G13, but it is only activated when a hidden product marking instruction is received. First, the 12 products are packaged into medium boxes, and then the 6 medium boxes are packaged into large boxes, requiring each large box to contain one hidden product. The specific steps are as follows: Defining workstation groups and random selection: The virtual workstation management module defines every 6 consecutive virtual workstations as a virtual workstation group (e.g., virtual workstations 1-6 are the first group, virtual workstations 7-12 are the second group, ...). For each virtual workstation group, the system randomly selects one location as the hidden product placement location. For example, the random algorithm selects the hidden product placement location for the first group as: the coordinates of the 8th product in the random sequence bound to the 3rd virtual workstation (i.e., virtual workstation 3) within that group. , ); Instruction Set Marking: When generating the control instruction set, the system adds a special "hidden item marker" to the coordinate instructions selected as hidden item placement positions. In the example above, in the control instruction set generated for virtual workstation 3, the instructions pre-assigned to the 8th robotic arm (G8) will be marked.

[0033] Collaborative execution of robotic arms: Conventional robotic arms (G1-G12): Their control logic is basically the same as in Example 1, but when the pre-assigned instruction they receive contains a "hidden marker," the robotic arm enters a "standby" state during the current work cycle and does not perform any grasping or releasing actions. For example, when virtual workstation 3 passes by G8, G8 does not move because the instruction contains a marker. Figure 4 As shown ( , The position is left empty because G8 does not perform any action.

[0034] Specialized robotic arm (G13): This robotic arm is configured to respond only to commands carrying a "hidden item marker". Coordinated by a motion controller, G13 is activated when a virtual workstation carrying the marker command (e.g., virtual workstation 3) arrives at G13's work area. It grabs a hidden item product T from its dedicated hidden item feeding area and, according to the coordinates in the command (… , ), and accurately place it into the corresponding packaging box of virtual workstation 3 ( , ) location, such as Figure 5 The hidden product T is placed in ( , A schematic diagram of ( ).

[0035] Through this mechanism, on the high-speed production line, a hidden item is randomly placed in one of every six boxes. The placement of regular products and hidden items is completed collaboratively by two types of robotic arms, ensuring a smooth process without interference and perfectly achieving the randomization, precision, and controllability of the hidden item's placement.

[0036] In the description of this invention, it should be understood that the directions or positional relationships indicated by up, down, left, right, inner end, outer end, one end, and the other end are based on the orientation or positional relationships shown in the accompanying drawings. They are only for the purpose of more clearly describing the technical solutions of this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and should not be construed as limiting this invention.

[0037] Although specific embodiments of the invention have been described in detail herein, they are given for illustrative purposes only and should not be construed as limiting the scope of the invention. Various substitutions, alterations, and modifications can be conceived without departing from the spirit and scope of the invention.

Claims

1. A method for random packaging of equal quantities of products based on virtual workstation mapping, characterized in that, Includes the following steps: S1. Based on the capacity N of the product packaging unit, generate multiple non-repeating random combination sequences, each of which is bound to a unique sequence identifier. It includes N product placement coordinates that correspond one-to-one with N fixed physical locations within the packaging unit. , ), where m and i are natural numbers; S2. In the virtual space of the packaging conveyor line, create virtual workstations that move synchronously with the physical packaging units. Each virtual workstation is bound to one of the random combination sequences and its sequence identifier. ; S3. At least N work areas are set up sequentially along the packaging conveyor line, and each work area is equipped with a robotic arm; a control instruction set is configured for each virtual workstation, the control instruction set containing N product placement coordinates in a random combination sequence bound to it, and the N product placement coordinates are pre-assigned to the at least N robotic arms respectively, so that when the virtual workstation reaches the work area corresponding to a certain robotic arm, the robotic arm executes the pre-assigned product placement coordinates; S4. The virtual workstation moves along the packaging conveyor line and passes through each of the work areas in sequence. Each time it passes through a work area, the robotic arm of that work area performs a product gripping and placing operation according to the product placement coordinates pre-assigned to the current virtual workstation, placing the product on the fixed physical position of the physical packaging unit corresponding to the coordinates. S5. After a virtual workstation has traversed all work areas, its corresponding physical packaging unit has placed N products and then entered the packaging workstation for sealing.

2. The method according to claim 1, characterized in that, The virtual workstations are distributed at equal intervals in the virtual space of the packaging conveyor line and move in the same direction and at the same speed as the packaging conveyor line.

3. The method according to claim 1 or 2, characterized in that, In step S3, the number of robotic arms Gz is set to be equal to the product capacity N, and each robotic arm is fixed to place one product.

4. The method according to claim 3, characterized in that, Each of the aforementioned work areas is physically fixed on the packaging conveyor line and is equipped with a robotic arm work origin; the robotic arm waits at the work origin and grasps the product, when a serial number is bound. When the virtual workstation arrives, the placement action is performed according to the pre-assigned product placement coordinates.

5. The method according to claim 1, characterized in that, This also includes the step of randomly adding a previously hidden product to the product packaging unit, specifically: S01. Define a virtual workstation group consisting of M consecutive virtual workstations, where M≥2; S02. For each virtual workstation group, randomly select Q fixed physical locations as hidden item delivery locations, where 1≤Q<N; S03. Divide the robotic arms into N regular robotic arms and Q special robotic arms; the regular robotic arms are used to grasp and release regular products, and the special robotic arms are used to grasp and release hidden products. S04. In the control instruction set of step S3, add a hidden item marker to the product placement coordinates of the product selected as the hidden item placement location; S05. In step S4, when the robotic arm performs the placement operation: if the pre-assigned product placement coordinates do not have hidden product markings, the conventional robotic arm performs the conventional product placement; if the pre-assigned product placement coordinates have hidden product markings, the special robotic arm performs the hidden product placement, and the conventional robotic arm remains on standby during the work cycle corresponding to that coordinate.

6. The method according to claim 1, characterized in that, It also includes the step of adding a hidden product before the product is packed: after the packaging is completed in step S5 and before the packing station, at least one packaged unit containing the hidden product is mixed with multiple regular packaging units produced by steps S1 to S5 and packed together.

7. A virtual workstation mapping-based random packaging system for implementing the method as described in any one of claims 1 to 6, characterized in that, include: Packaging conveyor lines are used to carry and transport physical packaging units; A control server includes a random sequence generation module for performing step S1 as described in claim 1 to generate the random combination sequence; The virtual workstation management module is used to perform step S2 as described in claim 1, to create and manage the virtual workstation, and to generate the control instruction set; At least N robotic arms are sequentially arranged along the packaging conveyor line, with each robotic arm corresponding to a work area; and The motion controller is communicatively connected to the virtual workstation management module, the packaging conveyor line, and each of the robotic arms. It is used to synchronize the movement of the virtual workstation with the movement of the packaging conveyor line, and to command each robotic arm to perform product placement operations in the corresponding work area according to the control instruction set issued by the virtual workstation management module.

8. The system according to claim 7, characterized in that, The virtual workstation management module is configured to ensure that all virtual workstations maintain equal spacing in the virtual space and move synchronously with the packaging conveyor line.

9. The system according to claim 7 or 8, characterized in that, It also includes a hidden item management module, used to perform steps S01 to S04 as described in claim 5, generate a control instruction set containing hidden item markers, and coordinate the movements of the conventional robotic arm and the special robotic arm.

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