Isosynchronous-based production line glass positioning method, device, system and terminal

Abstract

The application provides a kind of production line glass positioning method, device and system based on isochronous synchronization, terminal, the method comprises: control photoelectric sensor from initial waiting position reciprocating motion along perpendicular to glass conveying direction, to the glass to be measured located in preset detection position is carried out side sensing, and corresponding sensing signal is generated;With preset high sampling frequency acquisition sensing signal, and the jump in sensing signal caused by glass side is used as trigger signal;In response to the trigger signal, based on isochronous synchronization real-time communication mechanism, the glass edge position encoding value output by absolute value encoder is acquired;Based on the glass edge position encoding value, and combined with the geometric specification information of the glass to be measured and target stacking position information, the positioning deviation value of the glass to be measured relative to target stacking station is calculated.The application realizes non-contact measurement of glass, and high-speed, high-precision positioning can be realized for single or double glass.

Description

Technical Field

[0001] This application belongs to the field of glass manufacturing technology and relates to a glass positioning method, device and system, and terminal for a production line based on isochronous synchronization. Background Technology

[0002] In the later stages of glass manufacturing, especially in the stacking process, precise positioning of glass sheets is crucial. To ensure that the glass can be accurately packed into standard-sized wooden crates in one go during stacking, the height and position of the edges of each glass sheet must be strictly aligned. This not only helps reduce subsequent manual intervention and lower labor costs but also significantly improves the safety and automation level of the production process.

[0003] However, in actual production, high-precision glass positioning faces multiple technical challenges. Currently, mainstream vertical stacking equipment typically uses a fixed path to grasp glass, making it impossible to dynamically adjust the lateral position of the glass during the grasping process, thus limiting stacking accuracy. Furthermore, glass, as a transparent material with high light transmittance and low reflectivity, presents significant difficulties for non-contact sensing and measurement due to its physical properties. In practical applications, sensors often fail to detect transparent edges due to their inability to reliably identify them; simultaneously, factors such as fluctuations in network communication load and inconsistent scanning cycles can cause communication delays, further exacerbating positioning errors and affecting overall stacking quality. Summary of the Invention

[0004] This application provides a method, apparatus, system, and terminal for positioning glass on a production line based on isochronous synchronization, which solves the problem of insufficient glass positioning accuracy in the prior art.

[0005] In a first aspect, this application provides a glass positioning method for a production line based on isochronous synchronization, comprising: controlling a photoelectric sensor to reciprocate from an initial waiting position along a direction perpendicular to the glass conveying direction to sense the edge of the glass to be tested located at a preset detection position and generate a corresponding sensing signal; acquiring the sensing signal at a preset high sampling frequency and using the transition edge caused by the glass edge in the sensing signal as a trigger signal; responding to the trigger signal, acquiring the glass edge position encoding value output by an absolute encoder based on an isochronous synchronization real-time communication mechanism; the absolute encoder is used to measure the vertical distance between the edge of the glass to be tested and a preset reference zero point position in real time; and calculating the positioning deviation value of the glass to be tested relative to the target stacking station based on the glass edge position encoding value and in combination with the geometric specifications of the glass to be tested and the target stacking position information.

[0006] In one implementation of the first aspect, in response to the trigger signal, acquiring the glass edge position encoding value output by the absolute encoder based on the isochronous real-time communication mechanism includes: configuring an isochronous synchronization task cycle based on the isochronous synchronization real-time communication protocol; within each isochronous synchronization task cycle, when a transition edge caused by the glass edge is detected in the sensing signal, a synchronization latching operation is immediately triggered to latch the glass edge position encoding value output by the absolute encoder at the moment of transition edge triggering; wherein the total delay time from the occurrence of the transition edge in the sensing signal to the latching of the glass edge position encoding value is less than a preset time threshold.

[0007] In one implementation of the first aspect, before controlling the photoelectric sensor to reciprocate from the initial waiting position along the direction perpendicular to the glass conveying direction, the method further includes: conveying the glass to be tested to a preset detection position via the conveying rollers of the glass production line, limiting the displacement of the glass to be tested in the conveying direction by a mechanical stop at the end of the conveying rollers, and fine-tuning the lateral position and orientation of the glass to be tested in the direction perpendicular to the conveying direction by a guide mechanism on both sides of the conveying rollers; and controlling the photoelectric sensor to move to the initial waiting position.

[0008] In one implementation of the first aspect, the method further includes: when the photoelectric sensor is in an initial waiting position, identifying the initial state of the photoelectric sensor; determining, based on the initial state, whether the photoelectric sensor can sense the glass under test; if the photoelectric sensor fails to sense the glass under test, controlling the photoelectric sensor to move from the initial waiting position along a first direction perpendicular to the glass conveying direction to perform edge sensing, and returning to the initial waiting position after completing edge sensing; otherwise, first controlling the photoelectric sensor to move from the initial waiting position in the opposite direction of the first direction to a preset reference zero point position, and then moving from the reference zero point position along the first direction to perform edge sensing, and returning to the initial waiting position after completing edge sensing.

[0009] In one implementation of the first aspect, calculating the positioning deviation value of the glass to be tested relative to the target stacking station based on the glass edge position encoding value, combined with the geometric specifications of the glass to be tested and the target stacking position information, includes: if the glass to be tested comprises a single piece of glass, then performing digital filtering and noise reduction processing on the glass edge position encoding value corresponding to the glass to be tested to obtain a processed glass edge position encoding value; based on the processed glass edge position encoding value, determining the vertical distance P between the edge of the glass to be tested and a preset reference zero point position; based on the geometric specifications of the glass to be tested, obtaining the width parameter W of the glass to be tested, and calculating the half-width value D of the glass to be tested; calculating the sum of the vertical distance P and the half-width value D to obtain the vertical distance M between the center position of the glass to be tested and the preset reference zero point position; based on the target stacking position information, obtaining the center position of the target stacking station and the vertical distance C between the center position of the target stacking station and the preset reference zero point position; calculating the difference between the vertical distance C and the vertical distance M to obtain the positioning deviation value ΔX.

[0010] In one implementation of the first aspect, calculating the positioning deviation value of the glass to be tested relative to the target stacking station based on the glass edge position encoding value, combined with the geometric specifications of the glass to be tested and the target stacking position information, includes: if the glass to be tested comprises at least two pieces of glass, then setting the interval distance between two adjacent pieces of glass; for any piece of the glass to be tested, performing digital filtering and noise reduction processing on the corresponding glass edge position encoding value to obtain a processed glass edge position encoding value; based on the processed glass edge position encoding value, determining the vertical distance P1 between the edge of the glass to be tested and a preset reference zero point position; and based on the geometric specifications of the glass to be tested, obtaining the positioning deviation value of the glass to be tested relative to the target stacking station. Measure the width parameter W1 of the glass; calculate the sum of the vertical distance P1 and the width parameter W1 to obtain the vertical distance M1 between the inner edge position of the glass to be tested and the preset reference zero point position; based on the target stacking position information, obtain the center position of the target stacking station and the vertical distance C between the center position of the target stacking station and the preset reference zero point position; calculate the difference between the vertical distance C and the vertical distance M1 to obtain the inner edge position deviation value ΔX1 of the glass to be tested; calculate half of the interval distance between two adjacent pieces of glass to obtain the half-interval distance K1; calculate the difference between the half-interval distance K1 and the inner edge position deviation value ΔX1 as the positioning deviation value ΔX.

[0011] Secondly, this application provides a glass positioning device for a production line based on isochronous synchronization, comprising: a photoelectric sensor for reciprocating motion from an initial waiting position along a direction perpendicular to the glass conveying direction to sense the edge of the glass to be tested located at a preset detection position and generate a corresponding sensing signal; a high-speed data input module configured as a slave input unit of a programmable logic controller (PLC), communicatively connected to the photoelectric sensor, for acquiring the sensing signal at a preset high sampling frequency and using the transition edge caused by the glass edge in the sensing signal as a trigger signal; a master station of the PLC, communicatively connected to the high-speed data input module and communicatively connected to an absolute encoder via a PROFINET bus, the absolute encoder being used to measure the vertical distance between the edge of the glass to be tested and a preset reference zero point position in real time; the master station of the PLC being used, in response to the trigger signal, to acquire the glass edge position encoding value output by the absolute encoder based on an isochronous synchronization real-time communication mechanism; and to calculate the positioning deviation value of the glass to be tested relative to the target stacking station based on the glass edge position encoding value, combined with the geometric specifications of the glass to be tested and the target stacking position information.

[0012] In one implementation of the second aspect, the method further includes: a conveyor roller conveyor for conveying the glass to be tested to a preset detection position; a mechanical stop is provided at the end of the conveyor roller conveyor for limiting the displacement of the glass to be tested in the conveying direction; guide mechanisms are provided on both sides of the conveyor roller conveyor for fine-tuning the lateral position and orientation of the glass to be tested perpendicular to the conveying direction; a detection bridge is erected above the conveyor roller conveyor; linear guide rails are provided on the left and right sides of the detection bridge, and at least one photoelectric sensor is installed on each side of the linear guide rail; a servo motor is connected to the linear guide rail for driving the photoelectric sensor to reciprocate along the corresponding linear guide rail, wherein the moving direction of the photoelectric sensor is perpendicular to the glass conveying direction.

[0013] Thirdly, this application provides a production line glass positioning system based on isochronous synchronization, comprising: a production line glass positioning device based on isochronous synchronization as described in any of the above claims, used to generate a positioning deviation value of the glass to be tested relative to a target stacking station; and a vertical stacker, communicatively connected to the production line glass positioning device based on isochronous synchronization, used to perform displacement compensation on the glass to be tested in a direction perpendicular to the glass conveying direction based on the positioning deviation value, so that the glass to be tested is aligned with the target stacking station.

[0014] Fourthly, this application provides a terminal, comprising: a memory for storing a computer program; and a processor for executing the computer program stored in the memory to cause the terminal to perform the method described in any of the above-mentioned embodiments.

[0015] As described above, the glass positioning method, apparatus, system, and terminal for production lines based on isochronous synchronization described in this application have the following beneficial effects:

[0016] (1) It realizes non-contact measurement of glass, effectively avoiding the wear, stress concentration or micro-cracks that may be caused to the glass edge by traditional contact probes or mechanical rulers during the measurement process;

[0017] (2) By adopting a high-speed data input module, the acquisition delay can be controlled at an extremely low level, thereby improving the acquisition speed and real-time performance of the sensor signal;

[0018] (3) Through the isochronous real-time communication mechanism, the timing jitter and uncertainty caused by the scanning cycle of the traditional programmable logic controller (PLC) are effectively eliminated, the repeatability and stability of the measurement results are greatly improved, and the overall positioning accuracy reaches the micron level. Attached Figure Description

[0019] Figure 1 The flowchart shown is an embodiment of a glass positioning method for a production line based on isochronous synchronization according to this application.

[0020] Figure 2 The diagram shows the conveying state of the glass under test on the conveyor rollers, according to an embodiment of this application.

[0021] Figure 3 This is a schematic diagram showing the conveying state of the glass under test on the conveyor rollers, which is another embodiment of this application.

[0022] Figure 4 The flowchart shown is another embodiment of the glass positioning method for a production line based on isochronous synchronization.

[0023] Figure 5 The diagram shown is a schematic of the data receiving process of a programmable logic controller according to an embodiment of this application.

[0024] Figure 6 The diagram shows the state of a single piece of glass on a conveyor roller according to an embodiment of this application.

[0025] Figure 7 The diagram shows the state of two pieces of glass on the conveyor rollers according to an embodiment of this application.

[0026] Figure 8 The diagram shown is a structural schematic of a glass positioning device for a production line based on isochronous synchronization, according to an embodiment of this application.

[0027] Figure 9 The diagram shown is a structural schematic of a glass positioning device for a production line based on isochronous synchronization, according to another embodiment of this application.

[0028] Figure 10 The diagram shown is a structural schematic of a glass positioning system for a production line based on isochronous synchronization, according to an embodiment of this application.

[0029] Figure 11 The diagram shown is a structural schematic of a terminal according to an embodiment of this application. Detailed Implementation

[0030] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. This application can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be noted that, unless otherwise specified, the following embodiments and features in the embodiments can be combined with each other.

[0031] It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this application. Therefore, the drawings only show the components related to this application and are not drawn according to the actual number, shape and size of the components in the actual implementation. In the actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0032] The following embodiments of this application provide a glass positioning method, apparatus, system, and terminal for a production line based on isochronous synchronization. This solution is applicable to the cold-end cutting section of automated float and rolled glass production lines, enabling high-speed, high-precision positioning of single or double-pane glass. This application exhibits high tolerance for lateral deviations in the glass stop position, effectively overcoming stacking misalignment problems caused by fluctuations in the incoming material position. It not only significantly improves the automation level and stacking accuracy of glass stacking but also provides key technical support for upgrading glass manufacturing lines towards lean and intelligent manufacturing.

[0033] Please see Figure 1 The above is a flowchart of a glass positioning method for a production line based on isochronous synchronization according to an embodiment of this application.

[0034] like Figure 1 As shown, this embodiment provides a glass positioning method for a production line based on isochronous synchronization, including the following steps S100 to S400.

[0035] In step S100, the photoelectric sensor is controlled to reciprocate from the initial waiting position along the direction perpendicular to the glass conveying direction to sense the edge of the glass to be tested located at the preset detection position and generate a corresponding sensing signal.

[0036] Specifically, in this embodiment, the photoelectric sensor uses a diffuse reflection photoelectric switch supporting phase-locked loop narrowband filtering frequency selection technology as the core sensing element. This type of photoelectric switch is highly sensitive to scattered light, and the phase-locked loop narrowband filtering frequency selection technology can significantly enhance its selective recognition capability of the signal returned from its own emitted light source, while effectively suppressing interference from strong ambient light. These characteristics make it particularly suitable for edge detection of transparent objects such as float or rolled glass with high transmittance and low reflectance, thereby greatly improving detection stability and accuracy.

[0037] The photoelectric sensor is mounted on a linear guide rail, which supports and guides the photoelectric sensor to perform a uniform horizontal scanning motion perpendicular to the glass conveying direction, ensuring that its motion trajectory remains orthogonal to the expected direction of the glass edge, thereby achieving efficient and accurate scanning of the glass edge.

[0038] Specifically, a synchronous belt is installed on the linear guide rail, and the photoelectric sensor is fixed on the belt. Driven by a side-mounted servo motor, the synchronous belt drives the photoelectric sensor to perform high-speed, stable reciprocating lateral movement along the guide rail. This structural design not only ensures the smooth movement of the photoelectric sensor during high-speed operation, but also effectively maintains its positioning repeatability, meeting the dual requirements of real-time performance and accuracy for glass production lines.

[0039] In addition, the length of the linear guide (i.e. the measurement stroke) is configured to cover the edge areas of various glass sheets that may appear on the glass conveyor rollers, ensuring that the edges of glass products, whether single or double sheets, or of different widths, can be completely scanned and reliably inspected.

[0040] In one embodiment of this application, before controlling the photoelectric sensor to reciprocate from the initial waiting position along a direction perpendicular to the glass conveying direction, the method further includes the steps S110 and S120.

[0041] In step S110, the glass to be tested is transported to a preset testing position by the conveyor rollers of the glass production line, and the displacement of the glass to be tested in the conveying direction is restricted by a mechanical stop at the end of the conveyor rollers, and the lateral position and orientation of the glass to be tested in the direction perpendicular to the conveying direction are finely adjusted by the guide mechanisms on both sides of the conveyor rollers.

[0042] Please see Figure 2 The image shows a schematic diagram illustrating the conveying state of the glass under test on the conveyor rollers according to an embodiment of this application. Please refer to... Figure 3 The image shows a schematic diagram illustrating the conveying state of the glass under test on the conveyor rollers, according to another embodiment of this application.

[0043] like Figure 2 and Figure 3As shown, the glass is conveyed from left to right. The servo motor drives the synchronous belt, which in turn drives the photoelectric sensor mounted on the linear guide rail to perform a high-speed, stable reciprocating lateral movement perpendicular to the glass conveying direction (i.e., laterally), so as to achieve precise scanning and positioning of the glass edge.

[0044] This implementation method, through the aforementioned positioning and fine-tuning measures, ensures that each piece of glass can be stably and repeatedly fed into the detection area while maintaining the correct spatial orientation. This adjustment mechanism effectively avoids false or missed detections caused by glass tilting or positional deviation, while also preventing the sensor beam from illuminating non-target objects such as roller conveyor rings and supports, thereby ensuring the purity and reliability of the measurement signal.

[0045] It should be noted that this embodiment can employ a static measurement mode, meaning that before performing edge detection, the glass to be tested must be completely stopped on the conveyor rollers before the sensor scan is triggered. This design effectively eliminates dynamic blurring, signal jitter, or positional shifts caused by glass movement, thereby improving the repeatability and reliability of edge detection.

[0046] In other embodiments, if the scanning speed of the photoelectric sensor is high enough, dynamic measurement can also be achieved, that is, real-time sensing and positioning of the edge position can be completed during the uniform glass conveying process.

[0047] In step S120, the photoelectric sensor is controlled to move to the initial waiting position.

[0048] In this embodiment, the initial waiting position can be set at a predetermined safe distance from the edge of the glass to be tested, in order to avoid mechanical interference or false triggering of the sensor during the glass's positioning process. The safe distance can be determined based on the maximum possible lateral offset of the glass and the sensor's dimensions. For example, the initial waiting position can be set to a lateral position 10 centimeters from the edge of the glass.

[0049] In some embodiments, the initial waiting position can also be flexibly set according to the production line layout and glass specifications.

[0050] Please see Figure 4 The above is a flowchart of a production line glass positioning method based on isochronous synchronization, according to another embodiment of this application.

[0051] like Figure 4 As shown, the glass positioning method for the production line based on isochronous synchronization further includes the following steps S121 to S124.

[0052] In step S121, when the photoelectric sensor is in the initial waiting position, the initial state of the photoelectric sensor is identified.

[0053] The initial state is used to characterize the initial relative positional relationship between the glass under test and the photoelectric sensor, specifically whether the sensor can sense the existence of the glass edge at the current position.

[0054] In step S122, based on the initial state, it is determined whether the photoelectric sensor can sense the glass under test.

[0055] In step S123, if the photoelectric sensor fails to detect the glass under test, the photoelectric sensor is controlled to move from the initial waiting position along a first direction perpendicular to the glass conveying direction to perform edge sensing, and returns to the initial waiting position after completing edge sensing.

[0056] In this embodiment, the statement "the photoelectric sensor failed to detect the glass under test" indicates that the glass may currently be located in an obstructed area, with a certain vertical distance between it and the glass edge. In this state, the sensor output signal remains at a low level. When the sensor moves along the first direction and detects the edge of the glass, its output signal jumps from low to high, forming a distinct rising edge.

[0057] In step S124, if the photoelectric sensor can sense the glass under test, the photoelectric sensor is first controlled to move from the initial waiting position in the opposite direction of the first direction to a preset reference zero point position, and then moves from the reference zero point position in the first direction to perform edge sensing, and returns to the initial waiting position after completing edge sensing.

[0058] In this embodiment, "the photoelectric sensor can sense the glass under test" indicates that it may currently be located within an obstructed area, such as directly above the glass plate. In this state, the sensor output signal remains at a high level. When the photoelectric sensor moves in the opposite direction of the first direction to a preset reference zero point position, its output signal changes from high level to low level, forming a distinct falling edge.

[0059] When the photoelectric sensor moves again from the reference zero point along the first direction, its output signal changes from low level to high level again.

[0060] In this implementation, the photoelectric sensor will trigger different working modes when it is in different initial waiting positions. The system adaptively selects the optimal scanning path through the above judgment mechanism, which avoids invalid travel and ensures that each edge measurement is based on a unified reference benchmark, thereby improving the consistency and repeatability of positioning.

[0061] In one embodiment of this application, to ensure the safe and reliable reciprocating scanning motion of the photoelectric sensor on the linear guide rail, limit switches are provided at both ends of the linear guide rail. The limit switches are implemented by limit protection sensors, which monitor the position of the photoelectric sensor in real time. When the sensor is detected to be approaching or reaching a preset travel boundary, a stop signal is sent to the control system to forcibly terminate the drive motor, thereby effectively preventing the sensor from mechanically colliding or derailing due to overtravel and ensuring long-term stable operation of the equipment.

[0062] This application enables non-contact measurement of glass, effectively avoiding the wear, stress concentration, or micro-crack risks caused to the glass edges by traditional contact probes or mechanical gauges during measurement. This not only ensures the integrity and appearance quality of glass products but also significantly reduces the scrap rate due to measurement. Furthermore, the absence of mechanical wear extends the service life of the sensor and measuring mechanism, correspondingly reducing maintenance costs.

[0063] In step S200, the sensing signal is acquired at a preset high sampling frequency, and the transition edge caused by the glass edge in the sensing signal is used as the trigger signal.

[0064] Specifically, the sensing signals can be acquired through a high-speed data input module. This high-speed data input module, serving as a slave input unit of a programmable logic controller (PLC), is dedicated to high-precision, high-response event capture. The hardware configuration of the high-speed data input module supports single-phase signal input mode, with a sampling frequency of 100 kHz to 200 kHz, corresponding to a signal scan period of less than 0.1 milliseconds (i.e., within 100 microseconds), providing microsecond-level time resolution.

[0065] If a conventional low-speed acquisition module is used, the signal sampling period is relatively long, which can easily lead to a lag in the determination of the edge triggering time, thus introducing position calculation errors. Especially in the case of high-speed glass conveying or rapid lateral movement of sensors, even a delay of tens of microseconds can cause millimeter-level positioning deviations, seriously affecting the stacking alignment accuracy. However, this application uses a high-speed data input module, which can control the acquisition delay to an extremely low level, improving the acquisition speed and real-time performance of the sensor signal.

[0066] In step S300, in response to the trigger signal, the glass edge position encoding value output by the absolute encoder is obtained based on the isochronous real-time communication mechanism.

[0067] Specifically, step S300 can be executed in the master station of the programmable logic controller. See also... Figure 5 The diagram shows a schematic of the data receiving process of a programmable logic controller according to an embodiment of this application.

[0068] The programmable logic controller (PLC) master station serves as the control core of the entire positioning system, communicating with the absolute encoder in real time via the PROFINET bus. The PROFINET bus not only ensures high bandwidth and low latency data transmission, but its built-in isochronous synchronization mechanism also ensures strict time alignment between the master station and the absolute encoder, thereby achieving microsecond-level synchronization accuracy between sensor events and position feedback.

[0069] In one embodiment of this application, in response to the trigger signal, the acquisition of the glass edge position encoding value output by the absolute encoder based on the isochronous real-time communication mechanism includes the following steps S301 and S302.

[0070] In step S301, the time synchronization task cycle is configured based on the time synchronization real-time communication protocol.

[0071] In step S302, during each of the isochronous synchronization task cycles, when a transition edge caused by the glass edge is detected in the sensing signal, a synchronization latching operation is immediately triggered to latch the glass edge position encoding value output by the absolute encoder at the moment the transition edge is triggered.

[0072] In this embodiment, the total delay time from the occurrence of a transition edge in the sensing signal to the latching of the encoded value at the edge of the glass is less than a preset time threshold.

[0073] If non-timely or asynchronous data acquisition methods are used, there will be an uncertain time offset between the sensor triggering time and the encoder sampling time, leading to data misalignment and introducing significant measurement errors. Especially on high-speed glass production lines, even microsecond-level timing deviations can translate into millimeter-level spatial errors.

[0074] This application effectively eliminates the timing jitter and uncertainty caused by the scanning cycle of traditional programmable logic controllers (PLCs) through an isochronous synchronous real-time communication mechanism. Regardless of changes in the glass feed rate, the system always captures the edge events of each piece of glass and its corresponding encoder position using the same synchronization reference, ensuring that all measurement data are generated within a unified and stable timing framework. This not only significantly improves the repeatability and stability of the measurement results but also enables the overall positioning accuracy to reach the micrometer (μm) level, fully meeting the high-precision, high-cycle positioning requirements of high-end float or rolled glass automated production lines.

[0075] In one embodiment of this application, the absolute encoder is used to measure the vertical distance between the edge of the glass under test and a preset reference zero point position in real time.

[0076] Specifically, the reference zero point is typically set as a fixed mechanical reference point on the equipment structure, such as the starting end of the guide rail, the positioning surface of the stop block, or the position of the calibration mark, serving as the global coordinate origin of the entire measurement system. All glass edge positions are calculated uniformly based on this reference, ensuring the comparability and consistency of positioning results for different batches and specifications of glass.

[0077] This application utilizes an absolute encoder, which offers significant advantages over incremental encoders: it internally stores unique coded information of the current position, allowing for immediate reading of the absolute position even after a power outage and restart, eliminating the need for zeroing or recalibration. This feature not only drastically reduces preparation time after production line start-up, shutdown, or fault recovery but also effectively avoids human error or mechanical drift risks introduced by repeated calibration, significantly improving system reliability, automation level, and long-term operational stability.

[0078] In step S400, based on the glass edge position encoding value, and combined with the geometric specifications of the glass to be tested and the target stacking position information, the positioning deviation value of the glass to be tested relative to the target stacking station is calculated.

[0079] This application is compatible with various specifications such as single-pane and double-pane glass, and can adapt to glass products with different widths, thicknesses and layouts. It has good process versatility and production line adaptability.

[0080] Please see Figure 6 The image shows a schematic diagram of the state of a single piece of glass on a conveyor roller according to an embodiment of this application.

[0081] In one embodiment of this application, the calculation of the positioning deviation value of the glass to be tested relative to the target stacking station based on the glass edge position encoding value, combined with the geometric specification information of the glass to be tested and the target stacking position information, includes the following steps S401 to S406.

[0082] In step S401, if the glass to be tested includes a single piece of glass, then the glass edge position encoding value corresponding to the glass to be tested is subjected to digital filtering and noise reduction processing to obtain the processed glass edge position encoding value.

[0083] In step S402, based on the processed glass edge position encoding value, the vertical distance P between the edge of the glass to be tested and the preset reference zero point position is determined.

[0084] In step S403, based on the geometric specifications of the glass to be tested, the width parameter W of the glass to be tested is obtained, and the half-width value D of the glass to be tested is calculated.

[0085] In step S404, the sum of the vertical distance P and the half-width value D is calculated to obtain the vertical distance M between the center position of the glass to be tested and the preset reference zero point position.

[0086] In step S405, based on the target stacking position information, the center position of the target stacking station and the vertical distance C between the center position of the target stacking station and the preset reference zero point position are obtained.

[0087] In step S406, the difference between the vertical distance C and the vertical distance M is calculated to obtain the positioning deviation value ΔX.

[0088] Please see Figure 7 The image shows a schematic diagram of the state of two pieces of glass on a conveyor roller according to an embodiment of this application.

[0089] In another embodiment of this application, the calculation of the positioning deviation value of the glass to be tested relative to the target stacking station based on the glass edge position encoding value, combined with the geometric specification information of the glass to be tested and the target stacking position information, includes the following steps S411 to S419.

[0090] In step S411, if the glass to be tested includes at least two pieces of glass, then the spacing between two adjacent pieces of glass is set.

[0091] Taking a typical double-pane glass stacking scenario as an example, the production process usually requires that the two panes of glass maintain a physical gap of no less than 20 centimeters in the transverse direction (i.e., perpendicular to the conveying direction). This value can be adjusted according to the layout of the production line equipment, the size of the gripper structure, and the internal cavity partitioning design of the packaging wooden box.

[0092] In step S412, for any piece of glass to be tested, the corresponding glass edge position encoding value is digitally filtered and denoised to obtain the processed glass edge position encoding value.

[0093] In step S413, based on the processed glass edge position encoding value, the vertical distance P1 between the edge of the glass to be tested and the preset reference zero point position is determined.

[0094] In step S414, the width parameter W1 of the glass to be tested is obtained based on the geometric specifications of the glass to be tested.

[0095] In step S415, the sum of the vertical distance P1 and the width parameter W1 is calculated to obtain the vertical distance M1 between the inner edge position of the glass to be tested and the preset reference zero point position.

[0096] In step S416, based on the target stacking position information, the center position of the target stacking station and the vertical distance C between the center position of the target stacking station and the preset reference zero point position are obtained.

[0097] In step S417, the difference between the vertical distance C and the vertical distance M1 is calculated to obtain the inner edge position deviation value of the glass under test. .

[0098] In step S418, half of the gap between two adjacent glass panes is calculated to obtain the half gap distance K1.

[0099] In step S419, the deviation value between the half-interval distance K1 and the inner edge position is calculated. The difference is taken as the positioning deviation value. .

[0100] In this implementation, by deeply integrating high-precision sensor data with structured process parameters, not only is accurate assessment of the individual positioning status of single or double-pane glass achieved, but reliable data support is also provided for the high-alignment stacking of the entire stack of glass. This effectively ensures that the glass can be packed into standard packaging wooden boxes in one go after unpacking, reducing manual intervention and improving the automation level and packaging yield of the production line.

[0101] It should be noted that the protection scope of the glass positioning method for production lines based on isochronous synchronization described in the embodiments of this application is not limited to the execution order of the steps listed in this embodiment. Any solution implemented by adding, subtracting, or replacing steps in the prior art based on the principles of this application is included within the protection scope of this application.

[0102] Please see Figure 8 The image shown is a schematic diagram of a production line glass positioning device based on isochronous synchronization according to an embodiment of this application.

[0103] like Figure 8 As shown in the figure, an embodiment of this application provides a glass positioning device for a production line based on isochronous synchronization, which includes a photoelectric sensor, a high-speed data input module, and a master station of a programmable logic controller.

[0104] Specifically, the photoelectric sensor is used to reciprocate from the initial waiting position along a direction perpendicular to the glass conveying direction to sense the edge of the glass to be tested located at the preset detection position and generate a corresponding sensing signal.

[0105] In this embodiment, two photoelectric sensors can be configured, each independently performing a reciprocating lateral scan within its corresponding detection range. For example, the left sensor is responsible for scanning the left edge region of the glass, while the right sensor is responsible for scanning the right edge region. This dual-sensor collaborative layout not only effectively expands the detection coverage of the system but also avoids the mechanical inertia and positioning error problems caused by the long-stroke, high-speed movement of a single sensor, while improving the parallel processing capability and overall efficiency of edge detection.

[0106] The high-speed data input module is configured as a slave input unit of a programmable logic controller and is communicatively connected to the photoelectric sensor. It is used to acquire the sensing signal at a preset high sampling frequency and use the transition edge caused by the glass edge in the sensing signal as a trigger signal.

[0107] The master station of the programmable logic controller (PLC) is communicatively connected to the high-speed data input module and to the absolute encoder via the PROFINET bus. The absolute encoder is used to measure the vertical distance between the edge of the glass under test and a preset reference zero point in real time. The master station of the PLC is used to respond to the trigger signal and, based on the isochronous synchronous real-time communication mechanism, acquire the glass edge position encoding value output by the absolute encoder. Based on the glass edge position encoding value, and in combination with the geometric specifications of the glass under test and the target stacking position information, the master station calculates the positioning deviation value of the glass under test relative to the target stacking station.

[0108] It should be noted that the structure and principle of the photoelectric sensor, high-speed data input module and programmable logic controller master station described in this embodiment correspond one-to-one with the steps in the above-mentioned glass positioning method for production lines based on isochronous synchronization, so they will not be repeated here.

[0109] In one embodiment of this application, the glass positioning device for the production line based on isochronous synchronization further includes a conveyor roller, a detection bridge, and a servo motor.

[0110] Specifically, the conveyor rollers are used to transport the glass to be tested to a preset testing position; the end of the conveyor rollers is provided with a mechanical stop to limit the displacement of the glass to be tested in the conveying direction; the two sides of the conveyor rollers are provided with guide mechanisms to finely adjust the lateral position and orientation of the glass to be tested in the direction perpendicular to the conveying direction.

[0111] The detection bridge is mounted above the conveyor roller conveyor; linear guide rails are provided on the left and right sides of the detection bridge, and at least one photoelectric sensor is installed on each of the linear guide rails.

[0112] The servo motor is connected to the linear guide rail and is used to drive the photoelectric sensor to reciprocate along the corresponding linear guide rail. The moving direction of the photoelectric sensor is perpendicular to the glass conveying direction.

[0113] Please see Figure 9 The image shown is a schematic diagram of a production line glass positioning device based on isochronous synchronization, according to another embodiment of this application.

[0114] like Figure 9 As shown in the embodiment of this application, the glass positioning device for a production line based on isochronous synchronization further includes an HMI (Human-Machine Interface) touchscreen. Operators can set or adjust key process parameters via the touchscreen interface, including but not limited to glass specification parameters, target stacking position, distance between adjacent glasses, safe waiting position, limit range, and synchronization task cycle.

[0115] It should be noted that the production line glass positioning device based on isochronous synchronization provided in this application can realize the production line glass positioning method based on isochronous synchronization described in this application. However, the implementation device of the production line glass positioning method based on isochronous synchronization described in this application includes, but is not limited to, the structure of the production line glass positioning device based on isochronous synchronization listed in this embodiment. All structural modifications and substitutions of the prior art made in accordance with the principles of this application are included within the protection scope of this application.

[0116] Please see Figure 10 The image shown is a schematic diagram of a production line glass positioning system based on isochronous synchronization according to an embodiment of this application.

[0117] like Figure 10 As shown in the embodiment of this application, the production line glass positioning system based on isochronous synchronization includes:

[0118] The production line glass positioning device based on isochronous synchronization as described in any of the above is used to generate the positioning deviation value of the glass to be tested relative to the target stacking station.

[0119] The vertical stacker is communicatively connected to the glass positioning device of the production line based on isochronous synchronization. It is used to compensate the displacement of the glass to be tested in the direction perpendicular to the glass conveying based on the positioning deviation value, so that the glass to be tested is aligned with the target stacking station.

[0120] In this implementation, the positioning device and the vertical stacker crane work together to form a closed-loop control system: the positioning device acts as the sensing end, providing high-precision, low-latency position feedback; the stacker crane acts as the execution end, dynamically adjusting the gripping or placement position according to deviation instructions. This closed-loop architecture effectively eliminates stacking misalignment problems caused by fluctuations in the glass material's incoming position, roller misalignment, or accumulated mechanical errors, significantly improving the edge alignment of the entire stack of glass.

[0121] Please see Figure 11 The image shown is a schematic diagram of the structure of a terminal according to an embodiment of this application.

[0122] like Figure 11 As shown, this application embodiment provides a terminal, including:

[0123] A memory for storing computer programs.

[0124] A processor, the processor being configured to execute a computer program stored in the memory, so as to cause the terminal to perform any of the methods described above.

[0125] In the embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, or methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative. For instance, the division of modules / units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple modules or units 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 of apparatuses or modules or units may be electrical, mechanical, or other forms.

[0126] The modules / units described as separate components may or may not be physically separate. The components shown as modules / units may or may not be physical modules; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules / units can be selected to achieve the objectives of the embodiments of this application, depending on actual needs. For example, the functional modules / units in the various embodiments of this application may be integrated into one processing module, or each module / unit may exist physically separately, or two or more modules / units may be integrated into one module / unit.

[0127] Those skilled in the art will further 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, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. 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.

[0128] The descriptions of the processes or structures corresponding to the above figures each have their own emphasis. For parts of a process or structure that are not described in detail, please refer to the relevant descriptions of other processes or structures.

[0129] The above embodiments are merely illustrative of the principles and effects of this application and are not intended to limit this application. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this application. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this application should still be covered by the claims of this application.

Claims

1. A glass positioning method for a production line based on isochronous synchronization, characterized in that, include: The photoelectric sensor is controlled to reciprocate from the initial waiting position along the direction perpendicular to the glass conveying to sense the edge of the glass to be tested located at the preset detection position and generate the corresponding sensing signal. The sensing signal is acquired at a preset high sampling frequency, and the transition edge caused by the glass edge in the sensing signal is used as the trigger signal. In response to the trigger signal, based on the isochronous real-time communication mechanism, the glass edge position encoding value output by the absolute encoder is obtained; the absolute encoder is used to measure the vertical distance between the edge of the glass under test and the preset reference zero point position in real time. Based on the glass edge position encoding value, and combined with the geometric specifications of the glass under test and the target stacking position information, the positioning deviation value of the glass under test relative to the target stacking station is calculated.

2. The method according to claim 1, characterized in that, In response to the trigger signal, based on the isochronous real-time communication mechanism, the glass edge position encoding value output by the absolute encoder is obtained, including: Configure the time-synchronization task cycle based on the isochronous real-time communication protocol; During each of the isochronous synchronization task cycles, when a transition edge caused by the glass edge is detected in the sensing signal, a synchronization latching operation is immediately triggered to latch the glass edge position encoding value output by the absolute encoder at the moment the transition edge is triggered; wherein the total delay time from the occurrence of the transition edge in the sensing signal to the latching of the glass edge position encoding value is less than a preset time threshold.

3. The method according to claim 1, characterized in that, Before controlling the photoelectric sensor to reciprocate from its initial waiting position along a direction perpendicular to the glass conveying direction, the following steps are also included: The glass to be tested is transported to a preset testing position via the conveyor rollers of the glass production line. The displacement of the glass to be tested in the conveying direction is restricted by a mechanical stop at the end of the conveyor rollers. The lateral position and orientation of the glass to be tested perpendicular to the conveying direction are finely adjusted by guide mechanisms on both sides of the conveyor rollers. Control the photoelectric sensor to move to the initial waiting position.

4. The method according to claim 1, characterized in that, Also includes: When the photoelectric sensor is in the initial waiting position, the initial state of the photoelectric sensor is identified; Based on the initial state, determine whether the photoelectric sensor can detect the glass under test; If the photoelectric sensor fails to detect the glass under test, the photoelectric sensor is controlled to move from the initial waiting position along a first direction perpendicular to the glass conveying direction to perform edge sensing, and returns to the initial waiting position after completing edge sensing; Otherwise, the photoelectric sensor is first controlled to move from the initial waiting position in the opposite direction of the first direction to a preset reference zero point position, and then moves from the reference zero point position in the first direction to perform edge sensing, and returns to the initial waiting position after the edge sensing is completed.

5. The method according to claim 1, characterized in that, Based on the glass edge position encoding value, and combined with the geometric specifications of the glass under test and the target stacking position information, the positioning deviation value of the glass under test relative to the target stacking station is calculated as follows: If the glass to be tested includes a single piece of glass, then the glass edge position encoding value corresponding to the glass to be tested is subjected to digital filtering and noise reduction processing to obtain the processed glass edge position encoding value. Based on the processed glass edge position encoding value, the vertical distance P between the glass edge to be tested and the preset reference zero point position is determined; Based on the geometric specifications of the glass to be tested, the width parameter W of the glass to be tested is obtained, and the half-width value D of the glass to be tested is calculated. Calculate the sum of the vertical distance P and the half-width value D to obtain the vertical distance M between the center position of the glass under test and the preset reference zero point position; Based on the target stacking position information, the center position of the target stacking station and the vertical distance C between the center position of the target stacking station and the preset reference zero point position are obtained. The difference between the vertical distance C and the vertical distance M is calculated to obtain the positioning deviation value ΔX.

6. The method according to claim 1, characterized in that, Based on the glass edge position encoding value, and combined with the geometric specifications of the glass under test and the target stacking position information, the positioning deviation value of the glass under test relative to the target stacking station is calculated as follows: If the glass to be tested comprises at least two pieces of glass, then the spacing between two adjacent pieces of glass is set. For any piece of glass to be tested, the corresponding glass edge position encoding value is digitally filtered and denoised to obtain the processed glass edge position encoding value. Based on the processed glass edge position encoding value, the vertical distance P1 between the glass edge to be tested and the preset reference zero point position is determined; Based on the geometric specifications of the glass to be tested, the width parameter W1 of the glass to be tested is obtained; Calculate the sum of the vertical distance P1 and the width parameter W1 to obtain the vertical distance M1 between the inner edge position of the glass under test and the preset reference zero point position; Based on the target stacking position information, the center position of the target stacking station and the vertical distance C between the center position of the target stacking station and the preset reference zero point position are obtained. Calculate the difference between the vertical distance C and the vertical distance M1 to obtain the inner edge position deviation value ΔX1 of the glass under test; Calculate half the distance between two adjacent glass panes to obtain the half-distance K1; Calculate the difference between the half-interval distance K1 and the inner edge position deviation value ΔX1, and use it as the positioning deviation value ΔX.

7. A glass positioning device for a production line based on isochronous synchronization, characterized in that, include: A photoelectric sensor is used to reciprocate from the initial waiting position along a direction perpendicular to the glass conveying direction to sense the edge of the glass to be tested located at a preset detection position and generate a corresponding sensing signal. The high-speed data input module is configured as a slave input unit of the programmable logic controller and is communicatively connected to the photoelectric sensor. It is used to acquire the sensing signal at a preset high sampling frequency and use the transition edge caused by the glass edge in the sensing signal as a trigger signal. The master station of the programmable logic controller is communicatively connected to the high-speed data input module and to the absolute encoder via the PROFINET bus. The absolute encoder is used to measure the vertical distance between the edge of the glass under test and the preset reference zero point position in real time. The master station of the programmable logic controller is used to respond to the trigger signal and acquire the glass edge position encoding value output by the absolute encoder based on the isochronous synchronous real-time communication mechanism. Based on the edge position encoding value of the glass, and combined with the geometric specifications of the glass under test and the target stacking position information, the positioning deviation value of the glass under test relative to the target stacking station is calculated.

8. The apparatus according to claim 7, characterized in that, Also includes: The conveyor rollers are used to transport the glass to be tested to a preset testing position; the end of the conveyor rollers is provided with a mechanical stop to limit the displacement of the glass to be tested in the conveying direction; the two sides of the conveyor rollers are provided with guide mechanisms to finely adjust the lateral position and orientation of the glass to be tested perpendicular to the conveying direction. A detection bridge is erected above the conveyor roller conveyor; linear guide rails are provided on the left and right sides of the detection bridge, and at least one photoelectric sensor is installed on each of the linear guide rails. A servo motor, connected to the linear guide rail, drives the photoelectric sensor to reciprocate along the corresponding linear guide rail. The direction of movement of the photoelectric sensor is perpendicular to the glass conveying direction.

9. A glass positioning system for a production line based on isochronous synchronization, characterized in that, include: The production line glass positioning device based on isochronous synchronization as described in any one of claims 7 and 8 is used to generate a positioning deviation value of the glass to be tested relative to the target stacking station. The vertical stacker is communicatively connected to the glass positioning device of the production line based on isochronous synchronization. It is used to compensate the displacement of the glass to be tested in the direction perpendicular to the glass conveying based on the positioning deviation value, so that the glass to be tested is aligned with the target stacking station.

10. A terminal, characterized in that, include: The memory is used to store computer programs; A processor for executing a computer program stored in the memory to cause the terminal to perform the method of any one of claims 1 to 6.

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