Control method of PVC guardrail self-adaptive scratch prevention stacking system

Abstract

The application discloses a control method of a PVC guardrail self-adaptive scratch-preventing stacking system and relates to the technical field of stacking and packaging control. The method comprises four steps of state gating and beat alignment, soft contact and zero-sliding drop, pattern self-adaptation and material-path-tension linkage, and methodology sampling inspection and self-learning backfeeding. The four steps are as follows. Offline passing is combined with thermal imaging and visual hard threshold release and a slow cooling queue is rearranged. In the contact stage, a light touch, slight yielding, re-alignment, light drop and partition pressure release are executed in sequence. In the stacking and film winding, a pattern is selected according to edge perception, a material is set in a different direction, a path is optimized to have fewer sharp bends, and a synchronous tension is provided. In the outbound stage, a defect fingerprint is used to generate an action list for small-step backfeeding. The release permission, formula number and grabbing time label are connected throughout the process, and the path, tension and material orientation parameters and rule library are unified. The method reduces fog shadow marks and shear abrasion, reduces repeated handling and repair, and improves the consistency of the beat and the quality traceability.

Description

Technical Field

[0001] This invention relates to the field of stacking and packaging control technology, specifically a control method for a PVC guardrail adaptive anti-scratch stacking system. Background Technology

[0002] After extrusion and cooling, PVC guardrails enter the stacking and packaging process. Typical production lines employ a common strategy of timed release, fixed adsorption, fixed stacking patterns, and constant tension. Quality monitoring largely relies on end-point sampling and manual visual inspection. Because the finished products are still in a "scratch-prone sensitive period," their surface temperature gradient, electrostatic charge, and particle adhesion have not sufficiently decayed. Simultaneously, robot arrival time, end-point pad wear, pallet zone support conditions, and the curvature of the bundling / wrapping path fluctuate significantly between batches. Existing open-loop or semi-open-loop control often results in tangential micro-movement at the initial contact moment, passive dragging from the surface, concentrated edge and corner pressure, and interlayer misalignment. Environmental humidity, airflow in the duct, effective contact area of ​​the adsorption cup, and differences in end-point compliance can also alter the friction boundary in a short time, further amplifying the probability of fogging and streaks. Common surface defects in the industry include fogging, directional streaks, and edge and corner indentations. To mitigate these risks, production lines often use conservative speed reduction and excessive tension margins for stability, leading to decreased cycle time, increased energy consumption, increased material consumption, and still difficulty in ensuring cross-shift consistency and traceability. Most production lines use fixed corner guards and path templates. Although edge sensing and online geometric detection are provided, they lack feedforward correlation with release permits, adsorption strategies, and tension scheduling.

[0003] The existing PVC guardrail stacking and packaging processes lack integrated risk constraints and cross-process parameter consistency for the "sensitive period of easy abrasion": the stacking permission and cooling window are often approximated by empirical time, which cannot be aligned with the robot's grasping time; the first contact stage lacks the judgment of precursors of micro-vibration / friction and the zone unloading strategy, which can easily trigger micro-slippage in the "end / outside" stage; the interlayer stability mainly relies on fixed patterns and single isolation materials, which are difficult to adapt to the discreteness of length, mass and cross-section, and the curvature and tension rise of the bundling / wrapping path also lack linkage suppression of edge pressure and slippage signals; the sampling results are mostly unstructured records, which are difficult to point to specific parameters and form cross-batch constraints and traceability, and the cross-shift reuse of formulas lacks prohibition conditions and recovery criteria. This problem is particularly prominent in scenarios such as shift changes, mixed product specifications, cooling water temperature drift, and air cleanliness fluctuations: misalignment between gripping and cooling forces contact when thermal stability is insufficient, the superposition of particles and static electricity causes slight scratches, and the lack of linkage between pattern / material and path / tension amplifies the pressure on corners and interlayer shear. Ultimately, this manifests as increased unpredictability of appearance defects, expansion of defects during transportation, increased risk of rework and scrap, and customer complaints, as well as the need to sacrifice cycle time and production capacity for a long time in order to ensure yield. Summary of the Invention

[0004] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a control method for an adaptive anti-scratch stacking system for PVC guardrails. This method utilizes thermal imaging and visual hard thresholds for release and rearrangement of the slow-cooling queue. During the contact phase, early warning triggers execute gentle touch, micro-retreat, re-alignment, gentle placement, and zoned pressure release. Stacking and wrapping are performed using edge perception to select patterns, set anisotropic materials, optimize paths with fewer sharp bends, and synchronize tension. Upon exiting the station, a defect fingerprint-based action list is generated for small-step re-injection. Release permits, formula numbers, and grabbing time tags are integrated into the process, unifying path, tension, and material orientation parameters and rule bases. This method reduces fogging streaks and shear abrasion, minimizes repeated handling and rework, and solves the technical problems described in the background art.

[0005] (II) Technical Solution To achieve the above objectives, the present invention is implemented through the following technical solution: a control method for an adaptive anti-scratch stacking system for PVC guardrails, comprising: determining surface stability at the offline point using thermal imaging and visual detection; diverting and slow cooling for unstable areas; simultaneously removing static electricity and blowing with an air knife; replacing the end pad according to the wear threshold; issuing the release permit and formula number; and rearranging the slow cooling queue to align the grabbing and cooling windows. After the release permission is granted, the sequence of light touch-slight retraction-realignment-gentle placement is followed; the vacuum cup is controlled in zones, with the suction first applied to the surface; the tip is lowered and then the body is lowered; when a warning sign is detected, a short-distance retraction, deceleration, realignment, and placement are performed before placement. Choose column, interlocking, or mixed patterns based on length, weight, and cross-section; cover the decorative side with a film-coated partition, and layer anti-slip paper is stacked between layers; corner guards or saddles are provided at corners and edge sensors are integrated; plan a path with fewer sharp bends, and synchronize tension with the turntable; The tray is inspected at the station or by sampling according to the rhythm, and the haze, clarity and streaks are calculated to form a defect fingerprint; based on the fingerprint, an action list is generated, and the cooling, gentle placement, path and tension are adjusted within the safety boundary; the results are written back to the formula number and rule base, and cross-shift reuse is prohibited when anomalies occur frequently.

[0006] Furthermore, surface stability determination involves simultaneous acquisition of thermal imaging and visual detection with time alignment; entry into the grasping area is prohibited when either the electrostatic level or surface cleanliness fails to meet the standard; the release permission includes a threshold set and a grasping time tag, and records the gate control reason; the slow cooling queue is rearranged according to the grasping time tag.

[0007] Furthermore, the system performs a three-stage process of static electricity removal, directional air knife purging, and vacuum suction at the same station; the attitude alignment error is used to adjust the wind direction and suction angle; the end pad is recounted after the self-cleaning cycle and combined with the wear determination result to participate in the release permission judgment.

[0008] Furthermore, the sequence of light touch-micro retraction-realignment-light placement is triggered by multimodal precursor signals, including vibration, tangential micro-velocity and acoustic emission; the tip and rear body are used for placement and the end physical stop is set; the feed rhythm is aligned with the grasping time tag.

[0009] Furthermore, the vacuum cup is zoned and activated sequentially as it approaches the finish, and then released before leaving the surface during the removal phase; the zoned pressure command is driven by the fusion of local slippage risk and the edge sensing; when a high risk is detected continuously, the release permission for the next item to enter the gripping area is suspended.

[0010] Furthermore, based on length, weight, and cross-sectional elongation ratio, trays can be divided into column, interlocking, or mixed patterns, allowing for zone switching; smooth coated partitions are laid on the surface contact side, anti-slip paper is superimposed on the key layer, and the material orientation angle is set according to the expected tangential displacement.

[0011] Furthermore, the binding and wrapping path is generated with the principle of fewer sharp bends, and the minimum safety distance for sensitive finishes is set; the tension adopts a smooth rise-stable hold-gentle release curve and is synchronized with the turntable speed; when the edge sensor alarms, the tension and speed are adjusted simultaneously and the path is corrected.

[0012] Furthermore, small samples are collected under a fixed light source and field of view, and haze, clarity, and streaks are calculated to form the defect fingerprint. Based on the defect fingerprint, an action list is automatically generated, including extending the cooling window, tightening the placement speed, reducing tension, adding corner protectors, adjusting path curvature, and material orientation.

[0013] Furthermore, based on the action list, the formula parameters are updated within the safety boundary and the formula number is bound; cross-shift reuse is managed using a decreasing weighted risk temperature system, and cross-shift prohibition and mandatory cleaning or line stop investigation instructions are generated when the threshold is exceeded; reuse is restored according to preset unblocking conditions.

[0014] (III) Beneficial Effects This invention provides a control method for a PVC guardrail adaptive anti-scratch stacking system, which has the following beneficial effects: The production line uses thermal imaging and visual inspection to set a hard threshold, simultaneously performing static electricity removal, air knife purging, and vacuum suction. The slow-cooling queue is rearranged according to the robot's arrival position, and release permits and formula numbers are issued to reduce mis-release and repeated handling, ensuring that the workpieces entering the gripping area are in a stable initial state. Precursor triggers a light touch-micro-retraction-realignment-gentle placement, with vacuum cups depressurized in sections first, and the tip and body equipped with end physical stops; the camera uses a closed-loop small-step rework process to suppress contact impact and tangential drag, reducing the risk of end pad wear and fogging streaks, and keeping the cycle time undisturbed.

[0015] Choose from various stacking patterns, interlocking patterns, or mixed patterns based on size, weight, cross-section, and edge risk; use anisotropic material combinations between layers to raise the anti-slip threshold; use minimal sharp bends in the bundling and wrapping process, ensuring a smooth tension rise, stable maintenance, and gentle release synchronized with the turntable, dispersing peak line pressure and reducing corner indentations and misalignment. Parallel cameras with pressure and slip sensors are installed at critical corners for detection; any abnormalities are addressed by reducing tension, slowing down, or correcting the path, and inserting anti-slip layers or switching to more stable patterns as needed, eliminating problems at the stacking level and preventing spillover to transportation and warehousing.

[0016] Standardized samples are used to create defect fingerprints for haze, clarity, streaks, and artificial appearance. The system maps these fingerprints to a minimal and safe action list, automatically fine-tuning cooling windows, handling speeds, material orientation, path curvature, and tension plateaus. It also continuously optimizes the system by reversibly updating the default formula in small steps. Based on risk temperatures, cross-shift reuse is prohibited, and mandatory cleaning or line shutdown investigations are implemented. The rule base unifies formula numbers with acceleration / deceleration and turning restrictions for handling equipment, forming a consistent execution chain from release permission to outgoing inspection, improving traceability and consistency, and reducing reliance on experience. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the control method for the PVC guardrail adaptive anti-scratch stacking system of the present invention. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Please see Figure 1 This invention provides a control method for a PVC guardrail adaptive anti-scratch stacking system, comprising, Step 1: Using hard threshold and queue rearrangement as the main line, implement calculable gating and cycle alignment for the four states of the off-line workpiece: thermal, electrical, clean, and end padding. This allows the workpiece that has obtained release permission to enter the stacking position with the formula number and threshold set, providing a stable initial state for subsequent compliant contact and zero-slip drop.

[0020] After PVC guardrails are extruded, there is a risk of abrasion due to the temperature difference between the inside and outside, surface charge, and the amplified coupling of adhering particles. If the guardrail enters the gripping area when its surface stability is insufficient, the relative tangential micro-movement between the end and the finish will trigger low-threshold slippage, forming irreversible haze or streaks. Therefore, it is necessary to construct a gating function that unifies surface stability, electrostatic level, cleanliness, and end pad health into a single decision surface, and use a hard threshold to drive the flow, thereby transforming the decision of whether to allow passage from empirical rules into verifiable quantitative criteria.

[0021] First, based on the spatiotemporal aligned data of thermal imaging and visual inspection, surface temperature difference, static electricity and cleanliness are normalized and coupled to construct a more stringent soft maximum stability index during the sensitive period, and a one-step diversion is achieved by hard threshold decision.

[0022] To avoid misjudgment due to occasional fluctuations in a single feature, soft aggregation with entropy regularization is adopted, thereby maintaining differentiability at multi-feature boundaries and executionability at hard gating points: Among them, the collaborative stability index Used to determine whether a surface is stable. A larger value indicates greater instability; temperature difference normalization variable : Obtained by normalizing the surface-core temperature difference. Electrostatic normalization variable : Obtained from the surface potential through normalization, Cleanliness normalization variable : Obtained by normalizing the particle / fog pixel density Temperature difference weighting Electrostatic weight Cleanliness weight All are non-negative, and , ; Smooth Maximum Operator : Soft plus form, smooth parameters Controlling smoothness It nonlinearly amplifies each mode while maintaining differentiability.

[0023] After obtaining the synergy index, a one-step gating system is implemented using the health of the end-line cushion in conjunction with a hard threshold, ensuring forced diversion if any one of the criteria is not met: Among them, the gate trigger flag Boolean value , This indicates that the triggering of the shunt operation drives the slow-cooling shunt and the entry into the restricted area logic; stability threshold. Hard threshold for collaborative indexes Define the upper limit of the sensitive period; cooling completion rate. The completion rate obtained from the thermal field time series estimation is normalized to This characterizes whether the thermal stability required for grasping has been achieved. Cooling lower limit The minimum level of completion allowed before crawling. Ensure sufficient heat before contact; gasket wear ratio The degree of wear and tear, inversely derived from the health of the padding, is normalized to... Characterizes whether the liner is nearing failure; upper health limit. : Maximum allowable wear threshold ; Step function The Heaviside operator, when the input... Time to take Otherwise take Logical OR operator Boolean union, splitting occurs when any condition is met.

[0024] By coupling three types of risks—temperature difference, static electricity, and cleanliness—within the same criterion plane, and introducing a hard threshold for end-pad health, a one-step isolation is achieved for the sensitive period prone to abrasion. This eliminates potential tangential dragging sources before entering the gripping area, ultimately significantly reducing the false release rate and providing traceable trigger cause records.

[0025] Upon gating triggering, the system does not simply wait for cooling; instead, it simultaneously performs a three-stage operation of static electricity removal, directional air knife purging, and vacuum suction to rapidly attenuate surface charge and remove migratable particles. To avoid secondary contamination and passive dragging, a constrained saturation vector control law is employed to control the resultant force of the three-stage operation on tangential disturbances and correlate it with the workpiece attitude, wherein: Among them, the three-way control vector These are, respectively, the static electricity removal strength, the air knife injection pressure, and the vacuum flow rate. ; Saturation operator A saturation operator is a mapping that fully exposes the components of a vector, confining each component to its upper and lower bounds. It "clamps" any input to these safe bounds, trunculating it if it exceeds them, and allowing it to pass as is if it doesn't. The most common notation is... , indicating that the scalar Limited to the range Inside; for vectors Then apply the same clamping to each component.

[0026] Gain matrix : A third-order diagonal or sparse matrix, a set of positive definite matrices, setting the response sensitivity of each execution quantity; electrostatic error The difference between the static electricity level and the target upper limit is normalized to... Cleanliness error The difference between the cleanliness index and the target upper limit is normalized to... Attitude error The alignment error between the workpiece and the guide air / suction direction is normalized to... An attitude correction term that suppresses tangential drag; Workpiece normal With the direction of air / suction Unit vector; attitude error 0 represents perfect alignment. The "alignment degree" is explicitly quantified for use in the three-way control vector. Use. Weighting coefficients. Non-negative, sum is , The impact of the three types of errors on control.

[0027] By using constrained saturation vector control, the static removal, purging, and suction processes are transformed from parallel superposition to coordinated release, thus avoiding passive dragging and reverse eddy current adsorption caused by local overdrive. This reduces the static electricity and particle risk to an acceptable range within the gate in the shortest possible cycle time, ultimately significantly reducing the tangential friction prior required for subsequent grasping.

[0028] Even after achieving stability within the doorway, if the robot's grasping time and cooling completion window are misaligned, residual temperature differences will still cause low-speed tangential micro-movements, amplifying the probability of scratches. On the other hand, the health of the end effector pad gradually deteriorates with each contact cycle. If it is not proactively replaced within the cycle time, localized streaks will appear in the most easily overlooked near-qualified state. Therefore, it is necessary to simultaneously manage the cooling-positioning time geometry and the pad-contact life geometry, and to align the grasping and cooling windows using queue rearrangement to force replacement of the drive end effector pad and maintain rigid boundaries.

[0029] The wear of the end gasket does not increase linearly with the number of contact cycles, but is coupled with unit contact energy, tangential fretting, and surface temperature. To address this, health is updated using an energy-weighted discrete damage map, and replacement is triggered by a hard threshold, thereby upgrading the contact cycle statistics to condition-adaptive life.

[0030] Among them, pad health : No. Health status prior to the first contact, generalized to The initial value is close to The decision on whether to allow continued use is made; normal contact energy. Normal energy of a single contact To depict the matrix damage caused by indentation; Energy calibration constant Reference energy, Normalize the energy under different operating conditions; tangential micro-motion ratio : Obtained from the ratio of tangential velocity to threshold. Amplified wear caused by micro-slippage; surface temperature Instantaneous surface temperature upon contact ; Temperature Sensitivity Function : A fully disclosed monotone non-decreasing function can be taken as The truncation form, The higher the temperature, the faster the wear. Health decay coefficient Calibration coefficient Energy Index Non-negative exponent, Micro-amplification factor Non-negative coefficients .

[0031] When the padding health meets the requirements or Immediately replace if necessary, where the wear ratio is... And the lower limit of health The change event and operating condition summary will be written into the recipe number for subsequent statistics and refilling.

[0032] The contact counting is upgraded to a life estimation coupled with three factors: energy, micro-motion, and temperature. Therefore, it is more stringent for high-energy contacts under the same number of cycles. This forms a forced replacement strategy coupled with operating conditions, ultimately reducing hidden streaks caused by quasi-qualified gaskets.

[0033] To align the grabbing time with the cooling completion window within a limited cycle time, a discrete sorting optimization is constructed with misalignment penalty and repeated handling penalty as objectives. The prediction error of the robot's arrival time is included in the robustness term to ensure that the queue can maintain alignment under dynamic perturbation.

[0034] Among them, arrangement The dequeue order of the slow-cooling queue. For length The set of all permutations determines the gripping order of each workpiece; cost function Alignment optimization target Measuring queue quality; robot grasping time : No. The fetching time of the item in the current sorting order. Cooling complete window : The allowed time interval for fetching; a closed set of intervals; Cooling complete window It can be obtained by fitting a single exponential model to a thermal imaging sequence: Completeness Ambient temperature Surface temperature From thermal image; thermal decay constant Calibration; Given a target completion threshold ,Depend on Inverse solution obtained ; It is set by the beat and the lag limit.

[0035] Window distance function The fully disclosed projection distance is defined as follows: Measurement misalignment; number of repeated handling operations To achieve the additional handling count generated by the current sorting for this item, Penalty for repeated moves; position prediction error The absolute value or confidence radius of the deviation between the predicted and actual arrival time. Weight Non-negative, and normalizable. .

[0036] The solution employs a greedy, local swapping approximation strategy: first, sort by window distance as the primary order, then address the issue of generating large amounts of repeated swapping. The swapping is performed with restricted neighborhood swapping, while also incorporating the position prediction error. Larger workpieces are prioritized for placement in the middle of the window to improve robustness. After sorting, the system writes a capture time tag into the release permit flag and recipe number, causing downstream workstations to execute according to the tag's timing.

[0037] By transforming the grab-cool alignment into a measurable discrete optimization, the probability of misalignment can be significantly reduced within the cycle time constraint; thereby reducing redundant handling and waiting, and ultimately minimizing the slip trigger window while maintaining overall line throughput.

[0038] When the gate control is not triggered and the sorting is complete, the system generates a pass permission flag. and number the formula. With threshold set Sort labels Execution parameters Write the workpiece batch metadata together; if a gating trigger or a forced replacement of the liner occurs, record the gating reason and health trajectory, automatically import them into the slow cooling channel, and rearrange them in the next round of optimization.

[0039] Step 2: Using a compliant control and zoned pressure release strategy driven by early warning signs, ensure that the upper limit of normal contact energy is met. Upper limit of tangential micro-motion ratio Under the premise of achieving end-priority, zero-slip, and verifiable placement.

[0040] Even after release, PVC finishes may still exhibit slight temperature differences and residual stress. If contact is made within a quasi-stable window using a fixed feed, even minor vibrations can transform the microscopic roughness peaks of the end pad into tangential micro-amplifiers, thereby exceeding the upper limit of the tangential micro-amplifier ratio. Therefore, it is necessary to use a calculable pre-scratching index as the sole trigger signal in the contact critical zone, coupling feed rate, normal preload, and attitude fine-tuning into the same action. This solidifies the light touch-micro-retraction-realignment-light release sequence into a verifiable sequence, and links it to the formulation number. The operating parameters are mapped consistently.

[0041] In the critical contact zone, the system collects six-dimensional force / torque, proximity acceleration, vacuum flow disturbance and acoustic emission energy at the end in parallel, constructs a unified dimensional index that can reflect the impending collision in milliseconds, and achieves deceleration, retreat and repositioning with an exponentially suppressed velocity law.

[0042] Define the precursor index To use a weighted Hölder average, ensuring a rapid exponential increase when there is an anomaly in a single mode and maintaining smooth differentiability when there are mild anomalies in multiple modes: Among them, vibration amplitude End-effector triaxial acceleration envelope (Hilbert envelope after high-pass filter); tangential microvelocities Contact Frame Projection; acoustic emission energy Bandpass (100–500 kHz) energy density; Weight vector : The weights corresponding to acceleration amplitude, tangential velocity, and acoustic emission energy. And summed as Allocate contributions for each modality; observation vector These represent vibration amplitude, tangential micro-velocity, and acoustic emission energy density per unit time, respectively. This constitutes the precursor information base; element-wise exponentiation. : Power over each component of the vector To highlight abnormal peak values, This amplifies localized risks.

[0043] When brushing past the precursor index Exceeding the precursor threshold Immediately issue a micro-break distance order. With attitude angle fine-tuning And set the normal feed rate to exponentially suppressed. Simultaneously constrain normal contact energy Compared with tangential micro-motion ratio The triggering and deactivation timings are bound to the capture time tags. This ensures that the overall production line rhythm is not affected.

[0044] The pre-brushing index constructed using Hölder averages By compressing multimodal weak signals into a single trigger quantity, deceleration-retraction-realignment can be implemented before the actual slip occurs; thus significantly reducing tangential micro-movement at the moment of initial contact, and ultimately controlling the probability of abrasion within the stable window within a verifiable threshold.

[0045] In the approaching and exiting stages, maintaining constant adsorption in the vacuum cup will passively drag tangential perturbations. Therefore, a strategy of adsorption zone by zone, followed by release adsorption and then exiting, is adopted. This provides executable zoned pressure commands, mapping local slippage risk to pressure pullback magnitude, and utilizing the fully disclosed saturation operator from the previous step to ensure the execution amount remains within safe boundaries. Among them, the target pressure of the partition : No. Zone vacuum negative pressure command, (Both are constrained by negative upper bounds), driving adsorption intensity; saturation operator : Clip the input to a range The mapping ensures that the execution volume does not exceed the limit; reference pressure The baseline negative pressure of this batch of formula Provides nominal adsorption strength; partitioned coupling coefficient : Calibrated based on cup diameter, curvature, and material coating properties. , Adjust the first Risk sensitivity of the area; risk threshold Allowable local risk limit This triggers the boundary of the initial absorption.

[0046] Logistic function Smooth threshold mapping, slope parameter This smoothly transforms excessive risk into a pullback in pressure; the local slippage risk index Risk level that integrates local curvature, normal load, and tangential velocity. To characterize the likelihood of slippage in this area; Partitioned normal force Tangential velocity Surface principal curvature Calibration constant Weight .

[0047] By replacing fixed adsorption with pressure retraction based on risk perception, it can unload first in the edge area where tangential drag is most likely to occur; thus achieving first loosening and adsorption and then separation from the surface, ultimately minimizing the passive drag during the separation process and aligning it with the beat.

[0048] Speed ​​reduction and initial pressure release alone are insufficient to guarantee zero slippage, as the aircraft's attitude and contact point geometry determine whether the contact tangential velocity is completely zero. Therefore, under the constraints of the drop sequence of the front and rear ends and the physical stop at the ends, the linear velocity and angular velocity of the aircraft need to be calculated into a set of control quantities that ensure the contact tangential velocity is zero. After drop, a second check of the edges and corners is performed using visual geometry. If a slight deviation is detected, minor repairs and gentle re-dropping are carried out without damaging the finish.

[0049] In the case of end-to-end landing, the contact point velocity is determined by both the linear velocity and angular velocity of the aircraft. Let the contact Jacobian matrix be... Mapping the body's pose and velocity to the contact coordinate system aims to achieve a given normal feed... Under these conditions, the tangential component is made zero and the angular velocity amplitude is minimized to reduce the impact on the health of the end liner. Secondary wear.

[0050] The solution formula for least squares-Tikhonov regularization is given as follows: Among them, the body position velocity : The combination of linear velocity and angular velocity of the end effector; Contact Jacobi Matrix : Calculated from the current end contact geometry and the relationship between the front and rear support, a full-rank matrix is ​​used to map the body's pose and velocity to the contact point velocity; contact frame From the end normal With tangential base ; Contact point vector The displacement from TCP to the contact point is determined by using standard rigid body instantaneous velocity mapping, and the full rank condition is easily satisfied.

[0051] Normal feed rate Feed direction consistent with the drop direction. To ensure controlled normal contact; angular velocity vector : Attitude adjustment components; regularization weights Non-negative To suppress excessive angular velocity; Optimal pose velocity The calculated control quantity ensures that the tangential velocity is zero and the minimum norm is minimized.

[0052] During the solution process, the normal feed rate is... From the previous step of capturing time tags Upper limit of contact energy with normal direction Joint settings to ensure The end physical stop provides initial slip resistance in the length direction, significantly expanding the feasible region for the tangential zero-velocity condition.

[0053] By converting the zero tangential velocity into a calculable control variable through the minimum norm solution of the contact Jacobian, compatibility between end-landing priority and attitude compliance is achieved without sacrificing timing; thus reducing the impact on end-pad health. The cumulative wear and tangential micro-motion triggering ultimately yield a verifiable zero-slip drop trajectory.

[0054] After placement, the vision system constructs an observation vector using edge parallelism and corner error, and calculates the minimum pose increment with an analytical step size to ensure that the rework is completed in one step without damaging the finish. The closed-loop correction solution with weighted pseudo-inverse is given: Among them, pose increment Includes two-dimensional translation and small yaw / pitch angles. or Control of rework and realignment; visual Jacobi : A set of full-rank matrices that map small pose transformations to pixel / edge geometric errors, describing the sensitivity of errors to pose; weight matrix A set of positive definite matrices that assign different weights to the errors of edges, corners, and diagonals, highlighting key edges and corners; Damping coefficient Non-negative Suppressing noise and ill-conditioned solutions; damping Weighted least squares has been given; when In pathological conditions, take Adaptive: Minimum singular value ; Avoid secondary disturbances caused by over-correction; identity matrix :and Same order, regularization term; visual error vector The parallelism of the edges, the deviation of the corner points, and the diagonal misalignment error are obtained from online detection. , as the basis for repair.

[0055] During execution, if the visual error vector The weighted norm is below the acceptable threshold If the condition is met, the layer is confirmed as qualified and a qualified flag is written; otherwise, the position increment is used. Perform a minor rework and re-handling, and record the triggering cause, correction amount, and batch number. Write back to the recipe library for subsequent steps to link patterns, materials, and tension.

[0056] By replacing repeated trial and error with analytical step size, slight misalignment can be eliminated with the fewest number of actions; thereby reducing secondary risks caused by repeated handling and excessive adsorption, and ultimately maintaining the consistency of the entire production line rhythm while ensuring the appearance geometry.

[0057] The system records the pre-scratching index after each floor is dropped. Partition pressure command Optimal pose velocity With pose increment and with the formula number Binding. If the visual error vector If it passes, the zero-slip placement confirmation and edge-corner point pass mark for that layer will be output; if it fails, the rework record and trigger mode will enter the methodology sampling and self-learning backfeeding entry to support parameter adaptation in subsequent steps.

[0058] The specific connection is as follows: linking the distribution of precursory phenomena with regional risks. As an edge-aware input, the initial slope and plateau duration of the bundling tension rise-hold-release curve are set; the feasible region of zero-slip drop is mapped to the stability score of the pattern selector, enabling the key layer to automatically insert anti-slip material and optimize the path curvature; visual errors and rework rates are written back to the recipe library. In the pattern and tension rules, a cross-step collaborative closed loop of zero slip - stable pattern - gentle tension is formed, thereby continuing the low-risk initial state established in this step in subsequent steps.

[0059] Step 3: Under the premise of controlled edge risks, complete the unified decoupling and recoupling of stacking pattern selection, interlayer material orientation, and binding-wrapping path and tension, so that stability and appearance protection can achieve the same gain.

[0060] Significant differences in the length, weight, and cross-section of PVC railings can lead to batch dispersion within the same pallet, which can cause slippage and shearing at the interlayer interface. If a fixed pattern and single-material isolation layer are still used, edge scratches often occur at the corners or cantilever points of critical layers.

[0061] Therefore, it is necessary to use an edge-aware-driven scoring function to uniformly project the workpiece size and the contact-visual information from the previous step into the pattern feasible domain, and on this basis, significantly raise the slip threshold by combining anisotropic materials, so that the subsequent path and tension control have a more relaxed set of feasible options.

[0062] Before entering the interlayer stacking, the system considers factors such as guardrail length, unit weight, cross-sectional slenderness ratio, load distribution, and the risk level from the previous step (brush warning index). Local slip risk Visual error vector Construction and Pattern The relevant feature set is used to define the pattern scoring function in the form of a weighted power average, so that any significant anomaly in a single item will quickly raise the score, thereby triggering partition switching or pattern replacement: Among them, the pattern scoring function Measurement pattern In the current batch, considering the overall risk and stability costs, Used for selection and switching; feature set index set : Corresponding to length, weight, cross-section, edge risk, and window alignment respectively; weighting coefficient : Non-negative and sum is , Adjust the contribution of each feature; feature quantity : Length-support ratio normalization characteristic The penalty is insufficient support for the long cantilever under a given pattern; Feature quantity Weight-to-layout density normalization feature This reflects the interlayer pressure concentration of heavy components under the pattern; characteristic quantity Normalized characteristic of cross-sectional slenderness ratio Characterizes the deformation risk of easily tortuous sections under patterns; characteristic quantity Marginal risk characteristics From the precursor index Local slip risk With visual error vector The weighted convergence constitutes the pattern selection, transferring the edge information from the previous step to the pattern selection; feature quantity Window alignment features The window distance function from step one The result is a pattern of punishment and rhythmic alignment conflict; power exponent. Convexity index greater than 1 This amplifies the impact of anomalous features.

[0063] By employing a scoring function that is sensitive to anomalies and smooth and differentiable across multiple features, size, quality, cross-section, edge risk, and beat alignment are unified onto a single decision surface. Therefore, the system can proactively switch from columnar to interlocked or hybrid patterns in key partitions, thereby enhancing its resistance to misalignment without increasing the total number of components, ultimately providing a low-risk initial state for subsequent paths and tensions.

[0064] To reduce slip triggering and sustained slip, a smooth coated partition is laid between the layers on the finish side, and anti-slip paper is superimposed on the critical layer. The material texture orientation angle is set according to the expected tangential displacement direction. Considering the difference in friction coefficients of different materials under different orientations and the interaction with normal loads, a sustained slip threshold is defined: Among them, the continuous slip threshold The anti-slip threshold is determined by the interlayer material and orientation. Normal load The effective normal force at this interface layer. This is mapped to frictional potential; the coefficient of friction of a smooth coating. : When the orientation is parallel, friction is dominant; the coefficient of friction of anti-slip paper : Friction is dominant when the orientation is perpendicular; Orientation angle : The angle between the material texture and the expected tangential displacement direction, Smooth interpolation between two friction coefficients; risk suppression coefficient Non-negative This parameterizes the compensation strength for the risk threshold from the previous step; local risk mean. : This aggregates regional risks into hierarchical indicators.

[0065] By combining material orientation with the design of dual-material stacks, the threshold for continuous slippage is raised from a single friction constant to a function of load-orientation-risk compensation; therefore, it is less likely to enter continuous slippage under the same tension and path; ultimately, it provides greater parameter tuning margin when edge sensing anomalies occur.

[0066] Patterns and materials provide passive boundaries for stability, but if the binding and wrapping path has sharp bends with high curvature, or if the tension curve rises too quickly at the edge, it can still trigger corner compression and shearing. To address this, the path is optimized on the pallet coordinates with the principle of minimizing sharp bends, and the tension curve of smooth rise-stable holding-gentle release is synchronized with the turntable speed. The slope of the curve and the platform duration are adaptively adjusted using real-time signals from edge sensors to form a complete edge-sensing closed loop.

[0067] The centerline of the binding / wrapping is represented as a spatial curve with a normalized arc length parameter, aiming to suppress curvature peaks while avoiding sensitive finishes. A path cost functional is constructed and the optimal path is solved: Among them, path function : Normalized arc length parameterized path, pallet workspace, generating bundling / wrapping trajectory; curvature Path in arc length curvature at that point Penalty for sharp turns; distance function The minimum distance from the path to the set of sensitive finishes. Restrictions on detours; safe distance The minimum allowable distance for sensitive finishes. Weight Non-negative Balancing curvature penalty and detour cost; logistic function The slope parameter has already been disclosed in the previous step as a smooth threshold mapping. This comes at the cost of smoothly amplifying insufficient distance.

[0068] By using the square of curvature plus distance to smooth out obstacles, the optimal path naturally avoids high curvature and proximity to sensitive finishes; thus, the linear pressure fluctuations of the strip at corners and finish areas are significantly reduced; ultimately creating conditions for a stable platform for the tension curve.

[0069] After the optimal path is determined, the system uses normalized time. The belt tension is controlled using a hyperbolic tangent differential rise-plateau-release differentiable curve, and the slope factor is coupled with the edge risk index to enable rapid depressurization and deceleration when anomalies occur. Among them, tension curve : Belt tension command, Drive the binding / wrapping tension; minimum tension Safety lower limit Tension amplitude : Define platform height; time parameters : Normalization time, Starting point of ascent Release starting point :satisfy Define the platform interval; slope factor Non-negative Control the rate of rise / release and adapt it according to the edge risk index; edge risk index Hierarchical indicators obtained from pressure or slip sensing. ,adjust With respect to platform length; Marginal risk index: And the adaptive law is given: ;ensure Sufficient condition: .when As the speed increases, the slope becomes gentler, the plateau becomes longer, and the rotational speed decreases, which aligns with engineering intuition and can be calculated online.

[0070] Synchronization strategy: Turntable angular velocity Following the principle of constant linear pressure and synchronizing with the tension curve, when the edge risk index... When raising the turntable, appropriately reduce its angular velocity. And extend the platform range At the same time, the slope factor of the tension curve is... Lower it to obtain a gentler slope.

[0071] By replacing segmented abrupt changes with a differentiable cap-shaped curve, the instantaneous increase in tension in the edge region is strictly suppressed. Therefore, when pressure / slippage anomalies occur, the tension can be adjusted without oscillation and the path synchronization can be maintained. Ultimately, this significantly reduces the risk of indentations and streaks on corner protectors and sensitive finishes. Intended purpose: To enable tension to respond softly to risks and avoid secondary disturbances caused by hard thresholds.

[0072] After each layer is completed, the system outputs the optimal pattern. Material orientation angle Continuous sliding threshold Optimal path With tension parameter set and bind the recipe number. If the online geometric detection fails to meet the requirements for edge parallelism and diagonal misalignment, an anti-slip layer will be automatically inserted in the next layer, a more stable pattern will be switched, or the path will be retraced. Simultaneously, the abnormal location will be associated with the corresponding edge risk index. Write back so that the weights can be adjusted in the next loop. With tension plateau range.

[0073] Step 4: Generate defect fingerprints through standardized sampling inspections and drive the self-learning backflow of recipes and rule bases through the computable fingerprint → action list mapping to achieve continuously improving default recipes and rapid containment of anomalies within the safety boundary.

[0074] The final appearance quality of PVC finishes before transportation determines the cost of subsequent claims and repairs. Conventional manual sampling inspections are highly subjective and lack the ability to distinguish between micro-scratches, drag marks, and interlayer shear abrasion caused by fogging. Therefore, a small-scale sampling process completed within the pallet's outbound cycle is needed to transcribe fogging, clarity, streak directionality, and manual appearance scores into defect fingerprint vectors, and establish a one-to-one mapping with the aforementioned process state quantities. Thus, sampling inspection is no longer a static judgment of pass / fail, but becomes a small-step control signal driving the linkage between process parameters and path-tension-material processes.

[0075] Using a standard light source and fixed field of view imaging, representative samples are extracted from the same tray, the orientation-sensitive structural tensor energy is calculated and incorporated into haze and sharpness indices to form a verifiable quality score. Simultaneously, the haze component, sharpness component, streak direction energy density, and manual scoring are combined into a defect fingerprint vector to ensure consistency between subjective and objective information, and a quality score is defined: Among them, mass fraction A comprehensive defect measurement of the current tray sample. As the main indicator for grading and trigger thresholds; direction number The number of sampling directions used to capture the directionality of streaks / haze. Determine the directional resolution; directional weights The importance weights for each direction are non-negative and sum to 0. , Highlight key directions (such as the direction of transportation acceleration); Unit direction vector : No. Two-dimensional unit vectors in each direction, unit circle, projective structure tensor energy; Structure Tensor For sample images The gradient outer product of the second-order tensor smoothed by Gaussian (commonly in the form of a cross product of gradients) is a Gaussian smoothed tensor. Scale A smooth integral operator), a symmetric positive definite tensor set, describing the directionality and intensity of local texture; Structure tensor: Gaussian kernel ,scale ; For convolution, define the haze component (low-frequency energy percentage): Sharpness component (inverse normalized of edge intensity): Streak direction energy: Human rating Standardization to .

[0076] Image grayscale Input the single-channel intensity of the sample; the range can be normalized to... ;gradient Calculated in the pixel domain, using Sobel / Scharr; unit is "intensity / pixel"; outer product. : Obtained pixel by pixel Matrix field; elements are Gaussian kernel Standard deviation is Two-dimensional Gaussian (pixel); convolution symbol :and Spatial convolution serves to smooth and aggregate neighborhood gradients; structural tensor Pixel by pixel A symmetric positive definite matrix used to characterize the direction and intensity of local textures; its value is non-negative.

[0077] Discrete frequency vector Frequency index of a two-dimensional DFT; unit: "week / pixel"; Fourier spectrum :right Draw the complex spectrum after the two-dimensional discrete Fourier transform; Energy spectrum; frequency radius threshold The radius of the low-frequency circular domain (unit: ) (Same as above), used to delineate the "low-frequency energy" region; Low-frequency energy summation Summation within the frequency domain disk; haze component : Low-frequency energy percentage; the closer the value is to 1, the more concentrated the energy is in the low frequency range.

[0078] pixel domain The set of pixels representing the ROI (Region of Interest) included in the statistics; number of pixels. Total number of pixels within the ROI; gradient norm Pixel-wise gradient energy; mean gradient energy : Averaging of ROI; Sharpness component Using monotonic transformations to map "larger gradients" to "smaller numerical values" dimensionless indices facilitates integration with other components within the same domain. (Power exponent) Convexity index greater than 1 Amplify the energy in the abnormal direction; simultaneously define the defect fingerprint vector. The components are derived from haze measurement, sharpness measurement, streak energy density converged along the main direction, and human scoring, respectively. .

[0079] Using direction-sensitive structure tensor energy as the core, multi-source indicators are unified into a single mass fraction. Therefore, it can identify the difference between directional streaks and diffuse fog shadows at an early stage; thus providing a quantitative basis for subsequent action allocation; and ultimately enabling the sampling inspection process to enter a traceable and comparable engineering closed loop.

[0080] After obtaining the defect fingerprint vector, the system needs to select the fewest and most effective adjustment items within the boundaries of safety and timing, covering action dimensions such as extending the cooling window, tightening the release speed, reducing tension, adding corner protectors, limiting path curvature, and improving anti-slip level. To this end, an optimization model with sparse regularization and safety projection is constructed: Among them, action vector This includes the amplitude of each process action (such as the increase in cooling window size, the amount of tightening at the gentle placement speed, the decrease in tension, the increase in the number of corner protectors, the reduction in the upper limit of path curvature, the increase in anti-slip level, etc.), and the feasible range of actions. Generate an action list; optimal action vector. Optimization results are directly distributed to the corresponding workstations; default action baseline. From formula number The predetermined amplitude of the action, Provides sparse offset reference; fingerprint weights The importance weights of fingerprint components are non-negative and sum to 0. , Highlight key defect types; Feature shaping function :right Apply a monotonically increasing function to each component (optional) or power mapping ), This increases sensitivity to major defects; safe collection Take “box constraint ∩ linear coupling”: Box constraint: each action Linear coupling: such as "tension reduction" "and "speed reduction" The upper limit of the linkage. For the "box constraint" closed form, it is a component-by-component clipping; when linear coupling is involved, it is a quadratic programming projection, and the optimal solution can be obtained from the existing solver.

[0081] Hadamard Component-wise product mapping; sparse coefficients Non-negative Encourage small but forceful deviations in movement; safe projection. : To the safe set The Euclidean projection (which can be a closed mapping that minimizes the Euclidean distance). Includes upper limits for equipment acceleration / deceleration, upper limit for turntable angular velocity, upper limit for tension, and curvature constraints; safety penalty weights. Non-negative To suppress actions that cross the boundary.

[0082] An optimized model coupled with sparse regularization and secure projection directly translates defect fingerprints into a minimal action set, thus avoiding the throughput sacrifice caused by large-scale global parameter reduction; thereby quickly suppressing root cause defects without breaking the rule base; and finally achieving automatic closed-loop issuance of sampling inspection → action.

[0083] If the action list is not distilled into a parameter evolution trajectory, continuous improvement across batches will not be possible; however, radical full-parameter updates will introduce new risks. Therefore, it is necessary to update the formulation parameters in a small, reversible manner within the safety boundaries, and trigger mandatory cleaning / line shutdown investigations and cross-shift reuse suppression when anomalies occur frequently, so as to ensure learning while maintaining process steady state.

[0084] Organize the set of fully adjustable recipe parameters into a vector (including a set of thresholds). Speed-force threshold for gentle placement / repositioning / realignment, material orientation angle Path safety distance Tension parameter set (etc.), denoted as the formula parameter vector. .

[0085] The risk proxy function for the current batch (based on quality score) Defective fingerprints Marginal risk index Visual error vector (The result obtained by fusion) is denoted as Using mirror descent with safe set projection: Among them, the formula parameter vector : No. Batch parameter set, security set A unified parameter interface that runs through all four steps; Risk proxy function :Will , , , Weighted fusion convex proxy This indicates the direction of parameter updates;

[0086] Weight ; Generating function: Ensure geometric conformal preservation and vibration suppression of non-negative parameters.

[0087] Where: mass fraction : A quantitative index of appearance obtained by energy aggregation in the structural tensor direction. This is used to characterize the appearance condition of this batch. Defect fingerprint vector : These are dimensionless vectors representing haze, sharpness, streak direction energy, and human appearance rating, in order. Integer functions For monotonically increasing mappings of fingerprint components, a soft addition function is recommended. , Output This is used to amplify larger defect components. (Lexus 1) A scalar summation of components in the reshaped fingerprint. Marginal risk index. A hierarchical risk index obtained by weighting pressure, slippage, and visual edge error. Visual error vector : Geometric error vector of edge parallelism, corner deviation, and diagonal misalignment Weighted matrix Symmetric positive semi-definite weight matrix, used to calibrate the importance of each visual error; This is the weighted L2 norm. Weighting coefficients. Non-negative, sum to 1 Used to assign relative importance among the four categories of items.

[0088] Recipe parameter vector A unified set of adjustable parameters across steps (threshold set, touch and backoff settings, material orientation angle, path safety distance, tension curve parameters, etc.), taking the non-negative domain as needed, elements. Generating functions A strictly convex function (entropy term + 2-normative regularization) used to induce Bregman divergence while preserving proportional / nonnegative geometry. Regularization coefficients. Positive value, controls Euclidean shrinkage intensity.

[0089] Step length : Right now, Controlling the small-step update scale; Bregman divergence : generated by strictly convex functions Induced (desirable entropy-second norm mixing) ), To maintain the non-negative / proportional structure of parameters and suppress violent oscillations; safe collection The convex set, consisting of the upper limit of equipment acceleration / deceleration, the upper limit of turntable angular velocity, the upper limit of tension, the path curvature constraint, and the cooling window boundary, ensures executability.

[0090] By replacing simple Euclidean gradient descent with mirror descent, reversible small-step updates are achieved while maintaining the physical dimensions and proportional relationships of the parameters; thus balancing steady-state operation and learning speed; ultimately enabling formula numbering. The evolutionary trajectory monotonically converges towards the winning combination. To prevent problematic formulations from spreading across different shifts, a risk temperature index with decreasing weighting over time is constructed for cross-batch decision-making. When the risk temperature exceeds a threshold, cross-shift reuse of the formulation is immediately frozen, and a mandatory cleanup / line shutdown investigation is triggered. Among them, risk temperature : Measurement near Scalar of batch abnormal intensity, Cross-class suppression and line stop triggering basis; batch window The most recent batch number participating in the cumulative total. Time decay factor :lie in The decreasing coefficient assigns higher weight to more recent batches; gating weight : The trigger weight vector for the fingerprint component, non-negative and summed to . , Fingerprint reshaping : Single-shape vector; inner product : Match the weights with the fingerprint strength to the risk strength.

[0091] when At that time, the system executes cross-shift reuse prohibition and mandatory cleaning / line shutdown investigations, among which the threshold Certified by the quality system.

[0092] By aggregating anomalies over time using exponentially cooled risk temperatures, persistent problems can be identified without amplifying sporadic errors; this enables immediate freezing of problematic formulations and systematic investigation; ultimately preventing cross-shift propagation and shortening location time.

[0093] Output mass fraction when the pallet leaves the station. Defect fingerprint vector Optimal action vector Updated recipe parameter vector Risk temperature Each item is associated with a corresponding execution receipt and uniformly bound to the recipe number. .when At the same time, a cross-shift reuse prohibition mark, a mandatory cleaning instruction, and a line stop investigation form are generated; when and When a significant decrease occurs, the candidate set of winning combinations is entered. All updated records are added to the rule base to unify the acceleration, deceleration, and turning limits of the handling equipment with the pattern-path-tension-contact parameters.

[0094] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0095] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0096] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0097] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0098] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A control method for a PVC guardrail adaptive anti-scratch stacking system, characterized in that: include, At the offline point, surface stability is determined by thermal imaging and visual inspection. Unstable surfaces are shunted and slowly cooled, while static electricity is removed and air knife is used for purging. Replace the end gasket according to the wear threshold; issue the release permit and formula number, and rearrange the slow cooling queue to align the grab and cooling windows; After granting permission, follow the sequence of light touch - slight retraction - realignment - gentle placement; vacuum cup zone control, first release suction when it is off the surface; use tip-to-rear-body drop placement, short-distance retraction, deceleration, realignment and placement after detecting the precursor; Choose column, interlocking, or mixed patterns based on length, weight, and cross-section; cover the decorative side with a film-coated partition, and layer anti-slip paper is stacked between layers; corner guards or saddles are provided at corners and edge sensors are integrated; plan a path with fewer sharp bends, and synchronize tension with the turntable; The tray is inspected at the station or by sampling according to the rhythm, and the haze, clarity and streak are calculated to form a defect fingerprint; an action list is generated based on the fingerprint, and the cooling, gentle placement, path and tension are adjusted within the safety boundary; the results are written back to the recipe number and rule base, and cross-shift reuse is prohibited when anomalies occur frequently.

2. The control method for the PVC guardrail adaptive anti-scratch stacking system according to claim 1, characterized in that: Surface stability determination involves simultaneous acquisition of thermal imaging and visual detection with time alignment; entry into the grasping area is prohibited when either the electrostatic level or surface cleanliness fails to meet the standard; the release permission includes a threshold set and a grasping time tag, and records the gate control reason; the slow cooling queue is rearranged according to the grasping time tag.

3. The control method for the PVC guardrail adaptive anti-scratch stacking system according to claim 2, characterized in that: The system performs a three-stage process of static electricity removal, directional air knife purging, and vacuum suction at the same station; the attitude alignment error is used to adjust the airflow direction and suction angle; the end pad is recounted after the self-cleaning cycle and combined with the wear judgment result to participate in the release permission judgment.

4. The control method for the PVC guardrail adaptive anti-scratch stacking system according to claim 3, characterized in that: The sequence of light touch-micro retraction-realignment-light placement is triggered by multimodal precursor signals, including vibration, tangential micro-velocity and acoustic emission; the tip and rear body are used for placement and the end physical stop is set; the feed rhythm is aligned with the grasping time tag.

5. The control method for the PVC guardrail adaptive anti-scratch stacking system according to claim 4, characterized in that: The vacuum cup is zoned and activated sequentially as it approaches the finish, and then released before leaving the surface during the removal phase. The zoned pressure command is driven by the fusion of local slippage risk and edge sensing. When a high risk is detected continuously, the release permission for the next item to enter the gripping area is suspended.

6. The control method for the PVC guardrail adaptive anti-scratch stacking system according to claim 5, characterized in that: Based on length, weight, and cross-sectional elongation ratio, pallet zoning allows for column, interlocking, or mixed patterns, and enables zoning switching. A smooth film-coated partition is laid on the side of the surface to be in contact with the finish, anti-slip paper is superimposed on the key layer, and the material orientation angle is set according to the expected tangential displacement.

7. The control method for the PVC guardrail adaptive anti-scratch stacking system according to claim 6, characterized in that: The binding and wrapping path is generated with the principle of minimizing sharp bends, and the minimum safe distance for sensitive finishes is set; the tension adopts a smooth rise-stable hold-gentle release curve and is synchronized with the turntable speed; when the edge sensor alarms, the tension and speed are adjusted simultaneously and the path is corrected.

8. The control method for the PVC guardrail adaptive anti-scratch stacking system according to claim 7, characterized in that: Small samples are collected under a fixed light source and field of view. Haze, sharpness, and streaks are calculated to form the defect fingerprint. Based on the defect fingerprint, an action list is automatically generated, which includes extending the cooling window, tightening the placement speed, reducing tension, adding corner protectors, adjusting the path curvature, and adjusting the material orientation.

9. The control method for the PVC guardrail adaptive anti-scratch stacking system according to claim 8, characterized in that: Based on the action list, update the formula parameters and bind the formula number within the safety boundary; adopt a decreasing weighted risk temperature management system for cross-shift reuse, and generate cross-shift prohibition and mandatory cleaning or line stop investigation instructions when the threshold is exceeded; resume reuse according to preset unblocking conditions.

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