Flexible material dynamic positioning control system and method based on real-time length detection

Abstract

The application relates to a flexible material dynamic positioning control system and method based on real-time length detection, which comprises a transmission mechanism, a sensing mechanism, an encoder, an array air jet group, a peripheral system and a motion controller. The motion controller is connected to the sensing mechanism, the encoder, the array air jet group and the peripheral system. The motion controller is used for calculating the length and displacement of the flexible material according to the response time of the flexible material passing through the sensing mechanism and the conveying speed of the transmission mechanism, dynamically calculating the midpoint position of the flexible material according to the length and displacement of the flexible material, and determining the corresponding array air jet group of the flexible material according to the flexible material obtained by the peripheral system. When the center position of the flexible material reaches the position of the corresponding array air jet group, the corresponding array air jet group is triggered. The array air jet group can realize accurate air blowing sorting of the flexible material, realize adaptive adjustment of the air blowing position of the flexible material with different lengths, and meet the accurate sorting requirements of the flexible material with different lengths.

Description

Technical Field

[0001] This application relates to the field of textile waste sorting technology, specifically to a flexible material dynamic positioning control system and method based on real-time length detection. Background Technology

[0002] Textile waste refers to various waste materials generated during the production, processing, use, and disposal of textiles. It mainly includes scraps, waste yarn, used clothing, and dyeing waste. During the recycling process, textile waste needs to be sorted using waste textile conveyor lines. However, existing waste textile conveyor lines mostly use a fixed-interval air-blowing scheme for sorting, which has the following drawbacks:

[0003] 1. Poor adaptability: It cannot effectively handle materials with large length differences (100-800mm). Short materials are prone to being missed during blowing, and long materials are prone to being blown incorrectly (according to experimental tests, the error rate is 15%-20%).

[0004] 2. Inaccurate positioning: Due to the flexible nature of waste clothing, if the air blowing point is not aligned with the center of the clothing, it is very easy to cause the air to blow off-center, and the sorting success rate is only 80%-85%.

[0005] 3. Low efficiency: The fixed spacing design requires a safety distance, which reduces the density of the conveyor line and affects sorting efficiency.

[0006] While increasing the density of the air nozzles by increasing air pressure can improve coverage, it cannot solve the dynamic adaptation problem and is costly. Summary of the Invention

[0007] In view of the above problems, this application provides a flexible material dynamic positioning control system and method based on real-time length detection, which solves the problem that existing waste textile conveyor lines cannot effectively handle materials with large length differences, short materials are missed during blowing, and long materials are prone to misblowing.

[0008] To achieve the above objectives, the inventors provide a flexible material dynamic positioning control system based on real-time length detection, comprising:

[0009] The conveying mechanism is used to convey flexible materials;

[0010] A sensing mechanism is disposed on the transmission mechanism, and the sensing mechanism is used to sense the time it takes for flexible material to pass through the sensing mechanism;

[0011] An encoder is mounted on the transmission mechanism and is used to detect the transmission speed of the transmission mechanism.

[0012] Multiple array air spray groups are respectively arranged on one side of the conveying mechanism. The array air spray groups are used to sort the corresponding flexible materials on the conveying mechanism.

[0013] A peripheral system, which is used to acquire peripheral data of the flexible material on the transmission mechanism;

[0014] A motion controller is connected to the sensing mechanism, encoder, array air jet group, and peripheral system. The motion controller is used to calculate the length and displacement of the flexible material based on the response time of the flexible material through the sensing mechanism and the conveying speed of the transmission mechanism, and dynamically calculate the midpoint position of the flexible material based on the length and displacement of the flexible material. It also determines the corresponding array air jet group based on the flexible material obtained by the peripheral system. When the center position of the flexible material reaches the position of the corresponding array air jet group, the corresponding array air jet group is triggered.

[0015] In some embodiments, the peripheral system includes:

[0016] A vision system is provided, which is located at a first calibrated position on the transmission mechanism and is connected to a motion controller. The vision system is used to collect visual data of the flexible material on the transmission mechanism.

[0017] The NIR spectral system is located at the second calibration position of the transmission mechanism and is connected to the motion controller. The NIR spectral system is used to collect spectral data of the flexible material on the transmission mechanism.

[0018] The motion controller is also used to calculate the activation timing of the vision system and the NIR spectral system based on the response time of the flexible material through the sensing mechanism and the conveying speed of the transmission mechanism, and to adjust the sorting strategy of the flexible material through the visual data and spectral data of the flexible material collected by the vision system and the NIR spectral system.

[0019] In some embodiments, the sensing mechanism includes an infrared through-beam laser sensor.

[0020] In some embodiments, the array of air jets includes:

[0021] A straight-in connector, used for connecting to a gas source;

[0022] A solenoid valve, one end of which is connected to the straight-through connector;

[0023] Multiple nozzles are connected to the other end of the solenoid valve, and the multiple nozzles are vertically distributed and equidistantly arranged.

[0024] In some embodiments, the nozzle is a pointed nozzle.

[0025] In some embodiments, the sampling frequency of the sensing mechanism is 1 kHz.

[0026] In some embodiments, the air jetting parameters of the array air jet group for air sorting are 0.7 MPa and the duration is 400 ms.

[0027] In some embodiments, the motion controller is a multi-axis independent motion controller ZMC-306E.

[0028] Another technical solution is also provided: a dynamic positioning control method for flexible materials based on real-time length detection. This method is applied to the aforementioned dynamic positioning control system for flexible materials based on real-time length detection. The method includes the following steps:

[0029] When the sensing mechanism detects the flexible material on the transmission mechanism, it detects the front and back ends of the flexible material in real time and records the response time of the flexible material passing through the sensing mechanism.

[0030] The transmission speed of the transmission mechanism is obtained in real time by the encoder, and the displacement of the flexible material is calculated by integration.

[0031] Calculate the length of the flexible material based on the response time and transmission speed;

[0032] The midpoint position of the flexible material is dynamically calculated based on its length and displacement.

[0033] Data on flexible materials is acquired through peripheral systems to determine their corresponding array of air jets.

[0034] When the midpoint of the flexible material reaches the position of the corresponding array of air jets, the corresponding array of air jets is triggered.

[0035] In some embodiments, acquiring data about flexible materials through a peripheral system specifically includes the following steps:

[0036] The activation sequence of the vision system and NIR spectral system is calculated based on the response time of the flexible material passing through the sensing mechanism and the conveying speed of the transmission mechanism.

[0037] When the corresponding activation sequence is reached, the sorting strategy for flexible materials is adjusted based on the visual and spectral data of the flexible materials collected by the vision system and NIR spectral system.

[0038] Unlike existing technologies, the above technical solution first feeds the flexible materials to be sorted into a conveying mechanism. During the conveying process, a sensing mechanism detects the time it takes for the flexible materials to pass through the mechanism, an encoder detects the conveying speed, and a peripheral system acquires peripheral data of the flexible materials on the conveying mechanism. A motion controller calculates the length and displacement of the flexible materials based on the time it takes for them to pass through the sensing mechanism and the conveying speed, and dynamically calculates the midpoint position of the flexible materials based on their length and displacement. Based on the peripheral data of the flexible materials, the corresponding array of air jets is determined. When the center position of the flexible materials reaches the position of the corresponding array of air jets, the array of air jets is triggered to sort the flexible materials on the conveying mechanism. By determining the center position of the flexible materials through the sensing mechanism and encoder, the array of air jets can accurately sort the flexible materials by blowing air, and the blowing position can be adaptively adjusted for flexible materials of different lengths, meeting the requirements for accurate sorting of flexible materials of different lengths.

[0039] The above description of the invention is merely an overview of the technical solution of this application. In order to enable those skilled in the art to better understand the technical solution of this application and to implement it based on the description and drawings, and to make the above-mentioned objectives and other objectives, features and advantages of this application easier to understand, the following description is provided in conjunction with the specific embodiments and drawings of this application. Attached Figure Description

[0040] The accompanying drawings are only used to illustrate the principles, implementation methods, applications, features, and effects of specific embodiments of this application and other related content, and should not be considered as limitations on this application.

[0041] In the accompanying drawings of the instruction manual:

[0042] Figure 1 A schematic diagram of a flexible material dynamic positioning control system based on real-time length detection as described in a specific embodiment;

[0043] Figure 2 This is a schematic diagram of another structure of the flexible material dynamic positioning control system based on real-time length detection described in the specific implementation method;

[0044] Figure 3 This is a schematic diagram illustrating the operating logic of the flexible material dynamic positioning control system based on real-time length detection as described in a specific implementation.

[0045] Figure 4 This is a schematic diagram of the control triggering timing diagram of the peripheral system described in the specific implementation method;

[0046] Figure 5A timing diagram illustrating a timing pulse triggering strategy for sorting two materials as described in a specific implementation;

[0047] Figure 6 This is a schematic diagram of one structure of the array air jet assembly described in a specific embodiment;

[0048] Figure 7 This is a schematic diagram of a process for dynamic positioning control of flexible materials based on real-time length detection, as described in a specific implementation.

[0049] The reference numerals used in the above figures are explained as follows:

[0050] 110. Transmission mechanism; 111. Servo motor; 112. Transmission belt;

[0051] 120. Sensing mechanism,

[0052] 130. Encoder

[0053] 140. Arrayed air jet assembly; 141. Straight connector; 142. Solenoid valve; 143. Nozzle.

[0054] 150. Peripheral systems

[0055] 160. Motion controller

[0056] 200. Flexible materials. Detailed Implementation

[0057] To illustrate the possible application scenarios, technical principles, implementable specific solutions, and achievable objectives and effects of this application in detail, the following description, in conjunction with the listed specific embodiments and accompanying drawings, provides a detailed explanation. The embodiments described herein are merely illustrative of the technical solutions of this application and are therefore intended to limit the scope of protection of this application.

[0058] In this document, the term "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The term "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment, nor does it specifically limit its independence or connection with other embodiments. In principle, in this application, as long as there are no technical contradictions or conflicts, the technical features mentioned in each embodiment can be combined in any way to form corresponding implementable technical solutions.

[0059] Unless otherwise defined, the technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the use of related terms herein is merely for the purpose of describing particular embodiments and is not intended to limit this application.

[0060] In the description of this application, the term "and / or" is used to describe the logical relationship between objects, indicating that three relationships can exist. For example, A and / or B means: A exists, B exists, and A and B exist simultaneously. Additionally, the character " / " in this document generally indicates that the preceding and following objects have an "or" logical relationship.

[0061] In this application, terms such as “first” and “second” are used only to distinguish one entity or operation from another, and do not necessarily require or imply any actual quantity, hierarchy or order relationship between these entities or operations.

[0062] Unless otherwise specified, the use of terms such as “comprising,” “including,” “having,” or other similar expressions in this application is intended to cover non-exclusive inclusion, which does not exclude the presence of additional elements in a process, method, or product that includes the stated elements, such that a process, method, or product that includes a list of elements may include not only those defined elements but also other elements not expressly listed, or elements inherent to such a process, method, or product.

[0063] As understood in the Examination Guidelines, in this application, expressions such as "greater than," "less than," and "exceeding" are understood to exclude the stated number; expressions such as "above," "below," and "within" are understood to include the stated number. Furthermore, in the description of the embodiments in this application, "multiple" means two or more (including two), and similar expressions related to "multiple" are also understood in this way, such as "multiple groups" and "multiple times," unless otherwise explicitly specified.

[0064] In the description of the embodiments of this application, the space-related expressions used, such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "vertical," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," indicate the orientation or positional relationship based on the orientation or positional relationship shown in the specific embodiments or drawings. They are only for the purpose of describing the specific embodiments of this application or for the reader's understanding, and do not indicate or imply that the device or component referred to must have a specific position, a specific orientation, or be constructed or operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0065] Unless otherwise expressly specified or limited, the terms "installation," "connection," "linking," "fixing," and "setting," as used in the description of the embodiments of this application, should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral setting; it can be a mechanical connection, an electrical connection, or a communication connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two components or the interaction between two components. For those skilled in the art to which this application pertains, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0066] Please see Figures 1-3 This embodiment provides a flexible material dynamic positioning control system based on real-time length detection, including:

[0067] The conveying mechanism 110 is used to convey flexible material 200.

[0068] A sensing mechanism 120 is disposed on the transmission mechanism 110. The sensing mechanism 120 is used to sense the time it takes for the flexible material 200 to pass through it. The sensing mechanism 120 includes an infrared photoelectric sensor. By using an infrared photoelectric sensor as the sensing mechanism 120, the time it takes for the flexible material 200 to pass through the sensing mechanism 120 can be calculated by measuring the time the infrared signal of the infrared photoelectric sensor is blocked during its passage. The transmission mechanism 110 can be configured to include two transmission belts 112, with the sensing mechanism 120 positioned between the two belts. The infrared photoelectric sensor can be a Panasonic EX-19EB, which records the starting point of detection and calculates the length of the flexible material 200 based on its response time. In other embodiments, the sensing mechanism 120 can also be a gravity sensor, etc.

[0069] An encoder 130 is disposed on the transmission mechanism 110 and is used to detect the transmission speed of the transmission mechanism 110.

[0070] Multiple array air spray groups 140 are respectively arranged on one side of the conveying mechanism 110. The array air spray groups 140 are used to sort the corresponding flexible materials on the conveying mechanism 110.

[0071] Peripheral system 150 is used to acquire peripheral data of the flexible material on the transmission mechanism 110.

[0072] A motion controller 160 is connected to the sensing mechanism 120, encoder 130, array air jet group 140, and peripheral system 150. The motion controller 160 is used to calculate the length and displacement of the flexible material based on the response time of the flexible material passing through the sensing mechanism 120 and the conveying speed of the transmission mechanism 110, and dynamically calculate the midpoint position of the flexible material based on the length and displacement of the flexible material. It also determines the corresponding array air jet group 140 based on the flexible material obtained by the peripheral system 150. When the center position of the flexible material reaches the position of the corresponding array air jet group 140, the corresponding array air jet group 140 is triggered.

[0073] First, the flexible materials to be sorted are fed into the conveying mechanism 110. During the conveying process, the sensing mechanism 120 senses the time it takes for the flexible materials to pass through the sensing mechanism 110. The encoder 130 detects the conveying speed of the conveying mechanism 110, and the peripheral system 150 acquires the peripheral data of the flexible materials on the conveying mechanism 110. The motion controller 160 calculates the length and displacement of the flexible materials based on the time it takes for the flexible materials to pass through the sensing mechanism 120 and the conveying speed of the conveying mechanism 110, and dynamically calculates the length and displacement of the flexible materials based on these measurements. The center position of the flexible material is determined based on the peripheral data of the flexible material. When the center position of the flexible material reaches the position of the corresponding array air spray group 140, the corresponding array air spray group 140 is triggered to sort the flexible material on the conveying mechanism 110. By determining the center position of the flexible material through the sensing mechanism 120 and the encoder 130, the array air spray group 140 can accurately blow air to sort the flexible material, realize the adaptive adjustment of the blowing position for flexible materials of different lengths, and meet the requirements for accurate sorting of flexible materials of different lengths.

[0074] The motion controller 160 operates on a first-in, first-out (FIFO) principle. It records the length L of each flexible material as input data and calculates the output order for each material.

[0075] The motion controller 160 enables precise positioning of flexible materials, and its advantages in high-precision positioning of air blowing using axis control are as follows:

[0076]

[0077] The advantages of the motion controller's control modes include:

[0078] Fixed-point delay: The delay time is difficult to control precisely. Due to disturbances caused by the belt speed v, it is difficult to accurately determine the specific delay time.

[0079] Axis control:

[0080] High precision: The axis control accuracy reaches 7 decimal places.

[0081] Easy to debug: Each time the position is adjusted, only the length from the lower bound point to the reference point needs to be measured again.

[0082] Advantages of motion controller response time:

[0083] The response cycle of a PLC is closely related to its scan cycle. High-end PLCs on the market typically require a scan cycle of 10ms. This means that it takes 10ms to trigger the blowing command. However, the motion commands in a motion controller (equipped with an ARM Cortex A7 1GHz processor) have a low-level response time of 1ns in the motion buffer (which exists independently and is not affected by the program scan cycle).

[0084] In some embodiments, the peripheral system 150 includes:

[0085] A vision system is provided, which is located at the first calibration position of the transmission mechanism 110 and connected to the motion controller. The vision system is used to collect visual data of the flexible material on the transmission mechanism 110.

[0086] The NIR spectral system is located at the second calibration position of the transmission mechanism 110 and is connected to the motion controller. The NIR spectral system is used to collect spectral data of the flexible material on the transmission mechanism 110.

[0087] The motion controller is also used to calculate the activation sequence of the vision system and the NIR spectral system based on the response time of the flexible material passing through the sensing mechanism 120 and the conveying speed of the transmission mechanism 110, and to adjust the sorting strategy of the flexible material based on the visual data and spectral data of the flexible material collected by the vision system and the NIR spectral system.

[0088] Visual data of the flexible material on the transmission mechanism 110 is acquired by a vision system at a first calibration position, and spectral data of the flexible material on the transmission mechanism 110 is acquired by an NIR spectral system at a second calibration position. The motion controller calculates the activation sequence of the vision system and the NIR spectral system based on the corresponding time of the flexible material passing through the sensing mechanism 120 and the transmission speed of the transmission mechanism 110, thereby collecting peripheral data of the flexible material and determining a sorting strategy for the flexible material. Specifically, for example... Figure 4 In the control triggering timing diagram of the peripheral system shown, the positions of L1, L2, L3, and L4... are as follows:

[0089] L1: Trigger position calibration of the vision system;

[0090] L2: Trigger position calibration of the NIR spectroscopy system;

[0091] L3: Basic position calibration of solenoid valve assembly 1;

[0092] L4: Basic position calibration of solenoid valve assembly 2;

[0093] Among them, solenoid valve group 1 and solenoid valve group 2 are solenoid valve groups of different array air jet groups 140.

[0094] The timing management based on motion controllers has significant advantages, and its specific technical means are as follows:

[0095] Motion control offers significant advantages in timing management, and the specific technical methods are as follows:

[0096] It can reduce the reliance on hardware input detection signals, significantly reduce the number of input detection sensors, and increase the overall system stability.

[0097] When materials on the conveyor line pass point A, they trigger timing position pulses at points B, C, and D. Each piece of flexible material enters the timing management system. Each piece of flexible material triggers a corresponding event upon reaching its designated position. Following the FIFO queue management principle, multiple pieces of flexible material are processed continuously.

[0098] For example, when sorting material 1 and material 2, each flexible material will trigger a corresponding event when it reaches the corresponding position, as follows:

[0099]

[0100] And through software simulation, such as Figure 5 The two material sorting timing pulse triggering strategies shown are not only accurate, but also almost unrestricted by the triggering interval (theoretically, pulse widths greater than 5ms can be achieved); the traditional method has a large triggering interval, and the triggering interval needs to consider the following factors: the installation distance between sensors, the response time of the PLC to sensor feedback, and the safety distance to be reserved.

[0101] The timing pulse triggering strategy is briefly described below:

[0102] Axis definition: The main axis is a real axis, representing the servo motor 111 of the transmission mechanism 110; virtual axis B, this virtual axis processes the timing pulses of the vision system; virtual axis C, this virtual axis processes the timing pulses of the NIR spectral system; virtual axis D, this virtual axis processes the timing pulses of the solenoid valve 142 of the array air jet group 140.

[0103] Calculation of unit pulses per axis: Formula for calculating the unit pulse quantity per millimeter: u=1 / s*P*R; u: unit pulse quantity per millimeter; s: displacement of 1 revolution of servo motor 111 (mm); P: encoder 130 resolution of servo motor 111 (2^20); R: reduction ratio of geared motor.

[0104] Axis motion control: Define the main axis, virtual axis B, virtual axis C, virtual axis D... according to unit pulses (more virtual axes can be defined according to the required number of timing pulses); the main axis is the real axis, and axes B, C, and D are synchronized to the main axis to keep the virtual axes running synchronously with the main axis; then calibrate the timing positions (i.e., L1, L2, L3...); then start the main axis and begin real-time calculation of material coordinates:

[0105] Motion control triggering strategy based on timing pulses: When material 1 passes through point A (the time point when the photoelectric sensor acts), the system records the coordinate position of A1 and calculates the pulse trigger positions of B1, C1, and D1 according to calibration; similarly, when material 2 passes through point A (the time point when the photoelectric sensor acts), the system records the coordinate position of A2 and calculates the pulse trigger positions of B2, C2, and D2 according to calibration.

[0106] Observe the trigger pulse and its movement on the oscilloscope: Figure 5 In the example, material 1# is currently at position W1 and is running segment W1-D1. When it reaches D1, the timing pulse of D1 will be triggered. Figure 5 In the example, material #2 is currently at position W2 and is running the W2-B2 segment. When it reaches B2, the timing pulse of B2 will be triggered.

[0107] Specifically, in the example (clothing 1 length: 100mm, clothing 2 length: 800mm)

[0108] The belt speed (v=1.5m / s) is obtained through feedback from the encoder 130 on the servo motor 111.

[0109] The infrared sensor detects the front of the clothing and initiates 1kHz sampling.

[0110] The measurement for garment 1 was Δt = 0.067 s;

[0111] Clothing 2: Δt = 0.533s;

[0112] Calibrate system parameters:

[0113] The interaction location of the peripheral system is

[0114] L1 of point B in the peripheral system: 270mm.

[0115] Peripheral system point C, L2: 1170mm.

[0116] The reference position L3 of point D of the output array nozzle #1 is 3700mm.

[0117] The reference position L4 of point E of the output array nozzle #2 is 4700mm.

[0118] Controller calculation

[0119] The length of garment 1 is L = 1.5 × 0.067 = 0.1m.

[0120] The length of garment 2 is L = 1.5 × 0.533 = 0.8m.

[0121] Timing management triggers in the controller:

[0122] Data exchange between NIR spectral systems was processed at position L1:

[0123] Example as follows:

[0124] The system sends a trigger timing pulse signal at L1. The NIR spectroscopy system operates after receiving the trigger signal and feeds back data after a specified time of 250ms. The controller acquires the data information from the other system at a specified time (270ms after the trigger signal is activated).

[0125] Data interaction with the vision system was handled at L2 level:

[0126] Example as follows:

[0127] The system sends a trigger timing pulse signal at L2. The vision system also acquires the data information from the other party 270ms after the trigger.

[0128] Simultaneously, after being managed by the timing system, the data information from the acquired external systems is uniformly processed and judged by the controller.

[0129] Determine the output of the array fan group with sequence number 2;

[0130] Calculate the execution result:

[0131] Clothing 1 executes the array fan group with sequence number 2 (position L4+ L / 2).

[0132] Clothing 2 executes the array fan group with sequence number 1 (position L3+ L / 2).

[0133] Based on time-series management, the clothing on the delivery line is matched one-to-one with its corresponding execution location according to the FIFO principle; see the table below:

[0134]

[0135] The displacement of the clothing is calculated as s = ∫v(t)dt:

[0136] When garment 1 reaches L4+ L / 2, the vertical array air jet group with sequence number 2 will be automatically triggered.

[0137] When garment 2 reaches L3+L / 2, the vertical array air jet group with sequence number 1 will be automatically triggered.

[0138] (Air jet parameters: 0.7MPa per nozzle, duration 400ms).

[0139] Please see Figure 2 In some embodiments, the transmission mechanism 110 includes a servo motor 111 and a transmission belt 112;

[0140] The servo motor 111 is connected to the transmission belt 112 for transmission.

[0141] The encoder 130 is mounted on the servo motor 111.

[0142] The flexible material is transported via a transmission mechanism 110 consisting of a servo motor 111 and a transmission belt 112. The servo motor 111, in conjunction with an encoder 130, provides feedback on the speed v(t) of the transmission belt 112. The displacement of the flexible material is calculated by integration: s = ∫v(t)dt. The length is calculated by combining the passage time Δt of the flexible material (the time difference between the front end entering and the back end leaving the garment detected by the sensing mechanism 120) with the speed v(t): L = v(t) × Δt. The servo motor 111 is a Panasonic servo motor, which has a built-in high-precision photoelectric encoder 130 that records the movement position of each flexible material and participates in motion control.

[0143] Please see Figure 6 In some embodiments, the array of air jets 140 includes:

[0144] A straight-through connector 141 is used to connect to a gas source.

[0145] Solenoid valve 142, one end of which is connected to the straight connector 141.

[0146] Multiple nozzles 143 are connected to the other end of the solenoid valve 142.

[0147] The array of air jets 140 is connected to the air source via a direct plug. The connection between the air source and multiple nozzles 143 is controlled by a solenoid valve 142 to blow air onto flexible materials. The multiple nozzles 143 can handle flexible materials of different thicknesses.

[0148] In some embodiments, the nozzles 143 are vertically distributed and evenly spaced. By vertically distributing multiple nozzles 143 on the array air jet assembly 140 and ensuring equal spacing between each nozzle 143, the air blowing requirements for flexible materials at different heights can be met.

[0149] In some embodiments, the nozzle 143 is a pointed nozzle. Using a pointed nozzle 143 can further increase the blowing force of the gas, making it easier for flexible materials to be blown from the conveying mechanism 110 into the corresponding collection point.

[0150] In some embodiments, the motion controller is a multi-axis independent motion controller ZMC-306E. Using the multi-axis independent motion controller ZMC-306E can support the management of multi-task sequential tasks and data interaction with peripheral systems. In some embodiments, the sampling frequency of the sensing mechanism 120 is 1kHz to ensure the real-time performance and accuracy of length detection.

[0151] In some embodiments, the air jetting parameters of the array air jet group 140 for air sorting are 0.7 MPa and the duration is 400 ms. This ensures that the array air jet group 140 generates sufficient blowing force to blow the flexible material off the conveying mechanism 110.

[0152] Dynamic positioning and pneumatic blowing based on precise timing management:

[0153] Achieving dynamic positioning of the air blowing point: Based on precise timing management, and using an infrared sensor to detect the material length (L) in real time, combined with the conveyor line speed feedback from encoder 130, the position of the material's midpoint (L3 + L / 2) is dynamically calculated to ensure that the air blowing point is always located at the material's midpoint, avoiding offset. This achieves dynamic positioning of each flexible material on the production line. The measured positioning error is ≤3mm, far superior to traditional fixed-spacing sorting (error 30-75mm).

[0154] Adaptable to materials of different lengths (100-800mm): Whether the material is short (100mm) or long (800mm), the system can automatically adjust the blowing position to avoid missed or incorrect blowing.

[0155] The air blowing height adopts a vertical array air blowing (7cm spacing) to evenly cover materials of different heights (1~300mm): 3 vertically distributed air blowing points (1cm, 8cm, 15cm from the belt plane) are used to ensure that the airflow is evenly distributed in the vertical direction, which can adapt to materials of different stacking heights (such as flat clothes or rolled textiles).

[0156] Avoid uneven force distribution caused by single-point air blowing, and reduce the risk of material rolling or jamming.

[0157] High-frequency solenoid valve with fast response: The solenoid valve response time is ≤10ms, ensuring that the air pulse and motion control are strictly synchronized, thus improving positioning accuracy.

[0158] Supports 50Hz high-frequency triggering, adaptable to high-speed sorting (1.5m / s conveyor line speed).

[0159] Optimized pneumatic nozzle (stainless steel bullet shape): High pressure resistant and wear-resistant, using an extended stainless steel pointed nozzle with a pressure resistance of ≥1MPa, no deformation after long-term use, and a lifespan of over 10 million cycles. Straight airflow reduces scattering, improves airflow concentration, and ensures precise application of airflow force to the material. Uses an APC16-02 straight-insertion connector, suitable for 16mm pipe diameters, ensuring sufficient air pressure and flow rate (0.7MPa per nozzle) when three nozzles spray simultaneously. The 13mm external thread allows direct connection to high-frequency solenoid valves, preventing air leakage, providing high sealing performance, avoiding air pressure loss, and ensuring stable airflow.

[0160] Please see Figure 7 In another embodiment, a dynamic positioning control method for flexible materials based on real-time length detection is provided. The method is applied to the dynamic positioning control system for flexible materials based on real-time length detection described in the above embodiments. The method includes the following steps:

[0161] Step S710: When the sensing mechanism senses the flexible material on the transmission mechanism, the front and rear ends of the flexible material are detected in real time by the sensing mechanism, and the response time of the flexible material passing through the sensing mechanism is recorded.

[0162] Step S720: Obtain the transmission speed of the transmission mechanism in real time through the encoder, and calculate the displacement of the flexible material by integration;

[0163] Step S730: Calculate the length of the flexible material based on the response time and transmission speed;

[0164] Step S740: Based on the length and displacement of the flexible material, dynamically calculate the midpoint position of the flexible material;

[0165] Step S750: Obtain data on the flexible material through the peripheral system and determine its corresponding array of air jets;

[0166] Step S760: When the midpoint of the flexible material reaches the position of the corresponding array air jet group, the corresponding array air jet group is triggered.

[0167] First, the flexible materials to be sorted are fed into the conveying mechanism. During the conveying process, the sensing mechanism detects the time it takes for the flexible materials to pass through the mechanism, the encoder detects the conveying speed, and the peripheral system acquires the peripheral data of the flexible materials on the conveying mechanism. The motion controller calculates the length and displacement of the flexible materials based on the time it takes for the flexible materials to pass through the sensing mechanism and the conveying speed, and dynamically calculates the midpoint position of the flexible materials based on the length and displacement. Based on the peripheral data of the flexible materials, the corresponding array air spray group is determined. When the center position of the flexible materials reaches the position of the corresponding array air spray group, the corresponding array air spray group is triggered to sort the flexible materials on the conveying mechanism. By determining the center position of the flexible materials through the sensing mechanism and encoder, the array air spray group can accurately sort the flexible materials by blowing air, and the blowing position can be adaptively adjusted for flexible materials of different lengths to meet the requirements for accurate sorting of flexible materials of different lengths.

[0168] In some embodiments, acquiring data about flexible materials through a peripheral system specifically includes the following steps:

[0169] The activation sequence of the vision system and NIR spectral system is calculated based on the response time of the flexible material passing through the sensing mechanism and the conveying speed of the transmission mechanism.

[0170] When the corresponding activation sequence is reached, the sorting strategy for flexible materials is adjusted based on the visual and spectral data of the flexible materials collected by the vision system and NIR spectral system.

[0171] Visual data of the flexible material on the conveying mechanism is acquired by a vision system at a first calibration position, and spectral data of the flexible material on the conveying mechanism is acquired by an NIR spectral system at a second calibration position. The motion controller calculates the activation sequence of the vision system and the NIR spectral system based on the corresponding time of the flexible material passing through the sensing mechanism and the transmission speed of the conveying mechanism, and collects peripheral data of the flexible material to determine the sorting strategy for the flexible material. Specifically, for example... Figure 4 In the control triggering timing diagram of the peripheral system shown, the positions of L1, L2, L3, and L4... are as follows:

[0172] L1: Trigger position calibration of the vision system.

[0173] L2: Trigger position calibration of the NIR spectroscopy system.

[0174] L3: Basic position calibration of solenoid valve assembly 1.

[0175] L4: Basic position calibration of solenoid valve assembly 2.

[0176] Among them, solenoid valve group 1 and solenoid valve group 2 are solenoid valve groups of different array air jet groups.

[0177] The timing management based on motion controllers has significant advantages, and its specific technical means are as follows:

[0178] Motion control offers significant advantages in timing management, and the specific technical methods are as follows:

[0179] It can reduce the dependence on hardware input detection signals, significantly reduce the number of input detection sensors, and increase the overall system stability;

[0180] When materials on the conveyor line pass point A, they trigger timing position pulses at points B, C, and D. Each piece of flexible material enters the timing management system. Each piece of flexible material triggers a corresponding event upon reaching its designated position. Following the FIFO queue management principle, multiple pieces of flexible material are processed continuously.

[0181] For example, when sorting material 1 and material 2, each flexible material will trigger a corresponding event when it reaches the corresponding position, as follows:

[0182]

[0183] And through software simulation, such as Figure 5 The two material sorting timing pulse triggering strategies shown are not only accurate, but also almost unrestricted by the triggering interval (theoretically, pulse widths greater than 5ms can be achieved); the traditional method has a large triggering interval, and the triggering interval needs to consider the following factors: the installation distance between sensors, the response time of the PLC to sensor feedback, and the safety distance to be reserved.

[0184] The timing pulse triggering strategy is briefly described below:

[0185] Axis definitions: The main axis is a real axis, representing the servo motor of the transmission mechanism; Virtual axis B, this virtual axis processes the timing pulses of the vision system; Virtual axis C, this virtual axis processes the timing pulses of the NIR spectral system; Virtual axis D, this virtual axis processes the timing pulses of the array air jet solenoid valve.

[0186] Calculation of unit pulses per axis: Formula for calculating the unit pulse quantity per millimeter: u=1 / s*P*R; u: unit pulse quantity per millimeter; s: displacement of the servo motor in one revolution (mm); P: encoder resolution of the servo motor (2^20); R: reduction ratio of the geared motor.

[0187] Axis motion control: Define the main axis, virtual axis B, virtual axis C, virtual axis D... according to unit pulses (more virtual axes can be defined according to the required number of timing pulses); the main axis is the real axis, and axes B, C, and D are synchronized to the main axis to keep the virtual axes running synchronously with the main axis; then calibrate the timing positions (i.e., L1, L2, L3...); then start the main axis and begin real-time calculation of material coordinates:

[0188] Motion control triggering strategy based on timing pulses: When material 1 passes through point A (the time point when the photoelectric sensor acts), the system records the coordinate position of A1 and calculates the positions of B1, C1, and D1 according to calibration; similarly, when material 2 passes through point A (the time point when the photoelectric sensor acts), the system records the coordinate position of A2 and calculates the pulse trigger positions of B2, C2, and D2 according to calibration.

[0189] Observe the trigger pulse and its movement on the oscilloscope: Figure 5 In the example, material 1# is currently at position W1 and is running segment W1-D1. When it reaches D1, the timing pulse of D1 will be triggered. Figure 5 In the example, material #2 is currently at position W2 and is running the W2-B2 segment. When it reaches B2, the timing pulse of B2 will be triggered.

[0190] Specifically, in the example (clothing 1 length: 100mm, clothing 2 length: 800mm)

[0191] The belt speed (v=1.5m / s) is obtained through feedback from the servo motor encoder.

[0192] The infrared sensor detects the front of the clothing and initiates 1kHz sampling.

[0193] The measurement for garment 1 was Δt = 0.067s.

[0194] Clothing 2: Δt = 0.533s.

[0195] Calibrate system parameters:

[0196] The interaction location of the peripheral system is:

[0197] L1 of point B in the peripheral system: 270mm

[0198] Peripheral system point C, L2: 1170mm;

[0199] The reference position L3 of point D of the output array nozzle #1 is 3700mm;

[0200] The reference position L4 of point E of the output array nozzle #2 is 4700mm.

[0201] Controller calculation:

[0202] The length of garment 1 is L = 1.5 × 0.067 = 0.1m;

[0203] The length of garment 2 is L = 1.5 × 0.533 = 0.8m.

[0204] Timing management triggers in the controller:

[0205] Data interaction of the NIR spectral system was handled at position L1: Example follows:

[0206] The system sends a trigger timing pulse signal at L1. The NIR spectroscopy system operates after receiving the trigger signal and feeds back data after a specified time of 250ms. The controller acquires the data information from the other system at a specified time (270ms after the trigger signal is activated).

[0207] Data interaction with the vision system was handled at L2 level:

[0208] Example as follows:

[0209] The system sends a trigger timing pulse signal at L2. The vision system also acquires the data information from the other party 270ms after the trigger.

[0210] Simultaneously, after being managed by the timing system, the controller processes and judges the acquired data from external systems.

[0211] Determine the output of array fan group 2;

[0212] Calculate the execution result:

[0213] Clothing 1 executes array fan spray group 2 (position L4+ L / 2).

[0214] Clothing 2 executes array air jet group 1 (position L3+ L / 2).

[0215] Based on time-series management, the clothing on the delivery line is matched one-to-one with its corresponding execution location according to the FIFO principle. See the table below:

[0216]

[0217] The displacement of the clothing is calculated as s = ∫v(t)dt:

[0218] When garment 1 reaches L4+ L / 2, the vertical array air jet group with sequence number 2 will be automatically triggered.

[0219] When garment 2 reaches L3+L / 2, the vertical array air jet group with sequence number 1 will be automatically triggered.

[0220] (Air jet parameters: 0.7MPa per nozzle, duration 400ms).

[0221] Finally, it should be noted that although the above embodiments have been described in the text and drawings of this application, this should not limit the scope of patent protection of this application. Any technical solutions that are based on the essential concept of this application and utilize the content described in the text and drawings of this application, resulting in equivalent structural or procedural substitutions or modifications, as well as the direct or indirect application of the technical solutions of the above embodiments to other related technical fields, are all included within the scope of patent protection of this application.

Claims

1. A flexible material dynamic positioning control system based on real-time length detection, characterized in that, include: The conveying mechanism is used to convey flexible materials; A sensing mechanism is disposed on the transmission mechanism, and the sensing mechanism is used to sense the time it takes for flexible material to pass through the sensing mechanism; An encoder is mounted on the transmission mechanism and is used to detect the transmission speed of the transmission mechanism. Multiple array air spray groups are respectively arranged on one side of the conveying mechanism. The array air spray groups are used to sort the corresponding flexible materials on the conveying mechanism. A peripheral system, which is used to acquire peripheral data of the flexible material on the transmission mechanism; A motion controller is connected to the sensing mechanism, encoder, array air jet group, and peripheral system. The motion controller is used to calculate the length and displacement of the flexible material based on the response time of the flexible material through the sensing mechanism and the conveying speed of the transmission mechanism, and dynamically calculate the midpoint position of the flexible material based on the length and displacement of the flexible material. It also determines the corresponding array air jet group based on the flexible material obtained by the peripheral system. When the center position of the flexible material reaches the position of the corresponding array air jet group, the corresponding array air jet group is triggered.

2. The flexible material dynamic positioning control system based on real-time length detection according to claim 1, characterized in that, The peripheral system includes: A vision system is provided, which is located at a first calibrated position on the transmission mechanism and is connected to a motion controller. The vision system is used to collect visual data of the flexible material on the transmission mechanism. The NIR spectral system is located at the second calibration position of the transmission mechanism and is connected to the motion controller. The NIR spectral system is used to collect spectral data of the flexible material on the transmission mechanism. The motion controller is also used to calculate the activation timing of the vision system and the NIR spectral system based on the response time of the flexible material through the sensing mechanism and the conveying speed of the transmission mechanism, and to adjust the sorting strategy of the flexible material through the visual data and spectral data of the flexible material collected by the vision system and the NIR spectral system.

3. The flexible material dynamic positioning control system based on real-time length detection according to claim 1, characterized in that, The sensing mechanism includes an infrared through-beam laser sensor.

4. The flexible material dynamic positioning control system based on real-time length detection according to claim 1, characterized in that, The array of air jets includes: A straight-in connector, used for connecting to a gas source; A solenoid valve, one end of which is connected to the straight-through connector; Multiple nozzles are connected to the other end of the solenoid valve, and the multiple nozzles are vertically distributed and equidistantly arranged.

5. The flexible material dynamic positioning control system based on real-time length detection according to claim 4, characterized in that, The nozzle is a pointed nozzle.

6. The flexible material dynamic positioning control system based on real-time length detection according to claim 1, characterized in that, The sampling frequency of the sensing mechanism is 1 kHz.

7. The flexible material dynamic positioning control system based on real-time length detection according to claim 1, characterized in that, The air jetting parameters of the array air jet group are 0.7 MPa and the duration is 400 ms.

8. The flexible material dynamic positioning control system based on real-time length detection according to claim 1, characterized in that, The motion controller is a multi-axis independent motion controller ZMC-306E.

9. A dynamic positioning control method for flexible materials based on real-time length detection, characterized in that, The method is applied to the flexible material dynamic positioning control system based on real-time length detection as described in any one of claims 1-8, and the method includes the following steps: When the sensing mechanism detects the flexible material on the transmission mechanism, it detects the front and back ends of the flexible material in real time and records the response time of the flexible material passing through the sensing mechanism. The transmission speed of the transmission mechanism is obtained in real time by the encoder, and the displacement of the flexible material is calculated by integration. Calculate the length of the flexible material based on the response time and transmission speed; The midpoint position of the flexible material is dynamically calculated based on its length and displacement. Data on flexible materials is acquired through peripheral systems to determine their corresponding array of air jets. When the midpoint of the flexible material reaches the position of the corresponding array of air jets, the corresponding array of air jets is triggered.

10. The method for dynamic positioning control of flexible materials based on real-time length detection according to claim 9, characterized in that, The process of acquiring data on flexible materials through an external system specifically includes the following steps: The activation sequence of the vision system and NIR spectral system is calculated based on the response time of the flexible material passing through the sensing mechanism and the conveying speed of the transmission mechanism. When the corresponding activation sequence is reached, the sorting strategy for flexible materials is adjusted based on the visual and spectral data of the flexible materials collected by the vision system and NIR spectral system.

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