A fault detection device and method for a diverging assembly of an automated sorting apparatus

Abstract

This invention discloses a fault detection device and method for a diversion component of an automated sorting equipment. The device includes: a detection stand with a back plate on one side of its top; a diverter disposed on the top of the detection stand, with a straight motor and a steering motor installed on one side of the diverter; and a detection mechanism. This invention integrates the detection stand and the detection mechanism into one unit. The diverter can be placed directly on top of the detection stand for detection without disassembly and transport from the sorting line. After repair, retesting can be performed directly on the device, significantly reducing sorting line downtime. A single person can complete all operations, reducing manual labor costs. All components of the device adopt a standardized and modular design. The back plate provides a unified mounting base for the electrical control components. Each component is independently connected and detachable. Future upgrades can be made based on the diverter model, requiring only the replacement of the appropriate control system or components, without replacing the entire device, thus reducing equipment maintenance and upgrade costs.

Description

Technical Field

[0001] This invention relates to the field of diverter maintenance technology, specifically to a fault detection device and method for diverter components in automated sorting equipment. Background Technology

[0002] The sorting line diverter is the core execution equipment of the logistics automation system. Through the coordinated control of the steering drive motor and the straight drive motor, it can achieve ±90° multi-angle steering and straight conveying. It can accurately sort various packages such as soft packages and irregularly shaped items according to their destination and category. Its operational stability directly determines the operation efficiency of the sorting line. This type of diverter usually adopts a modular mechanical structure + PLC intelligent control system design. It needs to maintain stability under extreme working conditions of 24-hour continuous operation. Therefore, fault detection and rapid repair are the core requirements of sorting line operation and maintenance.

[0003] In existing technologies, the fault detection and repair of sorting line diverters suffer from several technical defects: First, there is no dedicated integrated fault detection device. Faulty diverters must be disassembled from the sorting line and sent to an independent repair area. After repair, they must be reinstalled on the sorting line for full-process verification. A single repair results in sorting line downtime of more than 2 hours, significantly reducing logistics sorting efficiency, and the manual disassembly, assembly, and transfer costs are high. Second, existing testing fixtures can only test the mechanical engagement accuracy of the diverter and lack the linkage of an electronic control system consistent with the actual sorting line, making it impossible to simulate sensor false triggering, motor stalling, and parameter mismatch. In real-world fault scenarios, test results often deviate significantly from actual operating conditions, leading to frequent recurrence of faults after repair. Thirdly, shunt repair involves complex skills such as mechanical adjustment, electrical control, and PLC program debugging. Existing training relies solely on paper manuals or video demonstrations, lacking an immersive hands-on environment, resulting in slow improvement in maintenance personnel's troubleshooting abilities. Fourthly, traditional testing platforms lack fault injection capabilities, making it impossible to assess the dynamic response capability of the shunt after repair. Furthermore, the messy wiring and scattered tool storage of repair equipment make it difficult for a single person to complete the repair operation, requiring multiple people to collaborate, further increasing maintenance costs.

[0004] To address the shortcomings of the existing technologies, this invention designs an automated sorting equipment diversion component fault detection device that integrates on-site testing, rapid repair, and hands-on training. Through a standardized electrical control structure and a visual operation interface, it enables rapid single-person testing and repair of the diverter without disassembly and transportation, significantly reducing downtime. It also has a fault simulation function and can serve as a hands-on training platform for maintenance personnel, solving many problems of the existing technologies. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a fault detection device and method for the diversion component of an automated sorting equipment. This addresses the technical problems in existing technologies, such as inaccurate test results of diverters, low efficiency in separating maintenance and testing processes, lack of professional practical training, and cumbersome maintenance operations requiring multiple personnel. The invention enables rapid on-site testing, maintenance, and fault simulation training of diverters.

[0006] To achieve the aforementioned goal of facilitating the maintenance of the sorting unit, the present invention provides the following technical solution: a fault detection device for the sorting component of an automated sorting equipment, comprising:

[0007] The testing stand has a back panel on one side of its top.

[0008] A flow divider is installed on the top of the testing bench, and a straight motor and a steering motor are installed on one side of the flow divider.

[0009] The testing mechanism includes a main power supply located on the top of the testing bench and a power distribution box, power converter, multi-function control card, PLC controller and touch screen located on the front of the back panel;

[0010] The main power supply is electrically connected to the power converter and the power distribution box. The power converter is electrically connected to the multi-function control card, the PLC controller, and the touch screen. The power distribution box is electrically connected to the straight motor and the steering motor. The PLC controller and the multi-function control card are connected via a data cable signal.

[0011] As a preferred embodiment of the present invention, the input terminal of the main power supply is connected to 380V AC power to the input terminal of the power converter, and the power converter converts the 380V AC power into 24V DC power to power the multi-functional control card, PLC controller, and touch screen.

[0012] The main power supply outputs 48V DC power, which is supplied to the straight motor and steering motor via the power distribution box.

[0013] As a preferred embodiment of the present invention, the display interface of the touch screen includes a parameter display unit for the set angle of the balance wheel, the current angle of the balance wheel, the set speed of the roller, and the current speed of the roller, as well as an operation control unit for zero-point calibration, return, and operation. The touch screen is bidirectionally connected to the PLC controller for signal transmission.

[0014] As a preferred embodiment of the present invention, the front side of the testing platform is provided with a plurality of tool storage boxes arranged vertically. The tool storage boxes are pull-out structures and have several partitioned chambers inside for classifying and storing maintenance tools.

[0015] As a preferred embodiment of the present invention, a cable routing frame is installed on the front side of the back plate of the testing platform, and the cable routing frame has a plurality of cable slots for combing and fixing cables inside.

[0016] As a preferred embodiment of the present invention, a support frame is also installed on the front side of the back plate. The support frame is disposed above the wiring I-beam frame, and the PLC controller and the touch operation screen are both snapped together with the support frame.

[0017] As a preferred embodiment of the present invention, the PLC controller pre-stores an offline splitter control system based on the TIA Portal V16 ladder diagram. The offline splitter control system supports independent parameter setting and operation testing of the splitter's steering and linear actions.

[0018] As a preferred embodiment of the present invention, the offline splitter control system supports inputting any angle value within the range of ±90° in the swing wheel setting angle parameter unit and any power value within the range of 0-100 in the roller setting speed parameter unit.

[0019] The present invention also provides a detection method for a fault detection device of a sorting component in an automated sorting equipment, comprising the following steps:

[0020] S1. Equipment Connection and Power Supply: Place the splitter on the top of the counter, complete the electrical connection of the main power supply, power converter, power distribution box, splitter, straight motor, steering motor and detection mechanism components, organize the cables and insert them into the cable tray, connect the main power supply to 380V AC power, output 24V DC power from the power converter to power the multi-function control card, PLC controller and touch screen, and output 48V DC power from the main power supply to power the straight motor and steering motor through the power distribution box;

[0021] S2. Steering action fault detection: Input the target angle value within ±90° through the swing wheel angle parameter setting unit on the touch screen, press and hold the zero point calibration unit, and the PLC controller sends a control signal to the steering motor through the multi-function control card to drive the distributor to complete the steering action. Observe whether the distributor swing wheel rotates normally, and check whether the target angle value set on the swing wheel on the touch screen is consistent with the current angle feedback value of the swing wheel. If they are consistent and the swing wheel rotates normally, the steering mechanism is fault-free; otherwise, the steering mechanism is faulty.

[0022] S3. Linear motion fault detection: Input the target power value within the range of 0-100 through the roller speed setting parameter unit on the touch screen, click the run operation unit, and the PLC controller sends a control signal to the linear motor through the multi-function control card to drive the distributor to complete the linear motion. Observe whether the distributor roller rotates normally, and check whether the roller set speed target value on the touch screen is consistent with the current speed feedback value of the roller. If they are consistent and the roller rotates normally, the linear mechanism is fault-free. Otherwise, the linear mechanism is faulty. After completing the test, adjust the roller set speed parameter value to 0 to stop the linear motor.

[0023] S4. Fault Repair and Retesting: If the test determines that the splitter assembly is faulty, use the repair tools in the drawer to complete the on-site repair. After the repair, repeat steps S2 and S3 until the steering and straight-line operation tests meet the requirements, and the fault repair is completed.

[0024] S5. Power off and reset the equipment: After testing or maintenance is completed, disconnect the 380V AC power supply of the main power supply, organize all connecting cables, and restore the testing device to its initial standby state.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] 1. This invention integrates the testing platform and testing mechanism into one unit. The diverter can be placed directly on the top of the testing platform to complete the test without disassembling and transporting it from the sorting line. After repair, it can be retested directly on the device, which greatly shortens the downtime of the sorting line. A single person can complete all operations, reducing the cost of manual collaboration. All components of the device adopt a standardized and modular design. The back plate provides a unified installation base for the electrical control components. Each component is independently connected and detachable. In the future, it can be upgraded according to the model of the diverter, only the appropriate control system or components need to be replaced, without replacing the entire device, thus reducing the cost of equipment maintenance and upgrades.

[0027] 2. The offline splitter control system pre-stored in the PLC controller of this invention can simulate the operating parameters of the actual sorting line, support turning tests at any angle within ±90° and straight-line tests at any power within 0-100. The touch screen synchronously displays the set parameters and actual operating parameters. Faults are determined by both parameter matching degree and equipment action status. The test results are highly consistent with the actual working state, avoiding fault reproduction. By customizing the parameters of the PLC control program, common fault scenarios in the actual sorting line, such as sensor false triggering, motor stall, and parameter mismatch, can be simulated. This not only evaluates the dynamic response capability of the splitter after maintenance, but also provides an immersive hands-on training environment for maintenance personnel, realizing the dual functions of a testing device and a training platform, and improving the fault diagnosis capabilities of maintenance personnel.

[0028] 3. This invention adopts a dual-power supply design with a single input and dual voltage output for the main power supply. The control circuit and the power circuit are powered independently to adapt to the power supply requirements of different components. The cable tray and cable slots enable standardized management and fixation of cables, avoiding cable tangling and pulling faults, and improving the anti-interference capability and operational stability of the device in the industrial field. The snap-fit ​​structure of the support frame enables quick disassembly and assembly of electrical control components, and the pull-out tool storage box enables classified storage and quick access to maintenance tools. The entire testing process does not require professional PLC programming skills, and ordinary maintenance personnel can operate it after simple training, reducing the operating threshold. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the detection mechanism of the present invention; Figure 3 This is a schematic diagram of the structure of the current splitter of the present invention; Figure 4 For the present invention Figure 2 Enlarged structural diagram at point A in the middle; Figure 5 This is a schematic diagram of the touch screen interface of the present invention.

[0030] In the diagram: 1. Testing bench; 2. Back panel; 3. Diverter; 301. Straight motor; 302. Steering motor; 4. Testing mechanism; 401. Main power supply; 402. Power distribution box; 403. Power converter; 404. Multifunctional control card; 405. PLC controller; 406. Touch screen; 5. Tool storage box; 6. Cable routing frame; 7. Cable tray; 8. Support frame. Detailed Implementation

[0031] 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.

[0032] Please see Figures 1-5 A fault detection device for a sorting component of an automated sorting equipment, comprising:

[0033] The testing stand 1 has a back plate 2 on one side of its top;

[0034] Among them, multiple tool storage boxes 5 are arranged vertically on the front side of the testing stand 1. The tool storage box 5 has a pull-out structure and has several partitioned chambers inside for classifying and storing maintenance tools.

[0035] Diverter 3 is located on the top of test bench 1. A straight motor 301 and a steering motor 302 are installed on one side of diverter 3.

[0036] The testing mechanism 4 includes a main power supply 401 located on the top of the testing platform 1, a power distribution box 402, a power converter 403, a multi-function control card 404, a PLC controller 405, and a touch screen located on the front side of the back panel 2.

[0037] The main power supply 401 is electrically connected to the power converter 403 and the power distribution box 402. The power converter 403 is electrically connected to the multi-function control card 404, the PLC controller 405 and the touch screen. The power distribution box 402 is electrically connected to the straight motor 301 and the steering motor 302. The PLC controller 405 and the multi-function control card 404 are connected via a data cable signal.

[0038] In this embodiment, the input terminal of the main power supply 401 is connected to 380V AC power to the input terminal of the power converter 403. The power converter 403 converts the 380V AC power into 24V DC power to power the multi-function control card 404, PLC controller 405, and touch screen. The multi-function control card 404 and the power distribution box 402 require the same main power supply 401 for power.

[0039] The main power supply 401 outputs 48V DC power, which is supplied to the straight motor 301 and the steering motor 302 via the power distribution box 402.

[0040] In this embodiment, the touch screen's display interface includes a parameter display unit for the balance wheel's set angle, current balance wheel angle, set roller speed, and current roller speed, as well as an operation control unit for zero-point calibration, return, and operation. The touch screen is bidirectionally connected to the PLC controller 405.

[0041] The shunt 3 can be controlled via the touch screen 406 to test the condition of suspected faulty parts and the shunt 3 assembly. It can also be used to test replacement parts before replacement to prevent the installation of faulty parts or assemblies.

[0042] In this embodiment, a cable routing frame 6 is installed on the front side of the back plate 2 of the test bench 1. The cable routing frame 6 has several cable slots 7 for combing and fixing cables, so as to avoid cable tangling and pulling failures and improve the anti-interference ability and operational stability of the device in the industrial field.

[0043] A support frame 8 is also installed on the front side of the back panel 2. The support frame 8 is set above the wiring I-beam frame 6. The PLC controller 405 and the touch operation screen are both connected to the support frame 8. The PLC controller 405 and the touch operation screen 406 are fixed by the support frame 8, thereby saving space and leaving the test bench 1 for the splitter 3.

[0044] In this embodiment, the PLC controller 405 is a Siemens S7-1500. The PLC controller 405 has a pre-stored offline splitter 3 control system based on the TIA Portal V16 ladder diagram. The offline splitter 3 control system supports independent parameter setting and operation testing of the splitter 3's steering and linear actions.

[0045] The offline splitter 3 control system supports inputting any angle value within the range of ±90° in the swing wheel setting angle parameter unit, and any power value within the range of 0-100 in the roller setting speed parameter unit.

[0046] In use, first connect the main power supply 401, power converter 403, and power distribution box 402 to various devices such as the splitter 3, touch screen 406, multi-function control card 404, PLC controller 405, straight motor 301, and steering motor 302 via cables. When testing is required, the offline splitter 3 program can be written to perform tests via the touch screen 406. The tests mainly focus on two parts: steering and straight movement. For the first part, steering, enter a number within ±90 degrees in the swing angle box, then press and hold the "zeroing" button and observe whether the splitter 3 wheel rotates. The swing wheel angle must match the current angle value. For the second part... For the straight-line test, enter any value from 0 to 100 for the roller speed. For example, if the speed is 50, the motor will drive the wheel to rotate at 50% power. Observe whether the wheel rotates and whether the feedback result of "current speed" is consistent. When the "roller speed" is changed to 0, the straight-line motor 301 will stop. This solves the problem of being unable to simulate the dynamic load, continuous operation and multiple working conditions of a real sorting line, which leads to inaccurate test results. The separation of maintenance and testing links means that after maintenance, the machine needs to be reinstalled on the sorting line for verification, which is inefficient. There is a lack of teaching and training modules for maintenance personnel, and the fault simulation capability is insufficient. In addition, disassembly and assembly are troublesome, the working area is small, and multiple people are required to cooperate, making it very inconvenient to use.

[0047] In addition, the device is designed with a testing system that simulates the actual logistics sorting environment. This system can continuously test the repaired distributor 3 under different operating conditions and load requirements, ensuring its stability and reliability under various working conditions. The testing system includes, but is not limited to, an adjustable-speed conveyor belt, various package simulation devices, and a real-time data monitoring interface to accurately measure and record the performance parameters of the distributor 3. The device is equipped with a dedicated maintenance area, integrating necessary tools and equipment to support rapid on-site diagnosis and repair. It also provides training for technicians through a visual teaching module, enhancing their troubleshooting capabilities. To ensure the authenticity of the tests, the platform is also configured with a control system that matches actual usage scenarios, allowing users to customize different test cases and abnormal situations to comprehensively evaluate the working status and durability of the distributor 3. The entire device adopts a modular design, facilitating upgrades and maintenance, while complying with relevant industry standards and safety regulations.

[0048] The present invention discloses a detection method for a fault detection device of a diversion component in an automated sorting equipment, comprising the following steps:

[0049] S1. Equipment Connection and Power Supply: Place the splitter 3 on the top of the counter and complete the electrical connection between the main power supply 401, power converter 403, power distribution box 402 and the splitter 3, straight motor 301, steering motor 302 and detection mechanism 4. Organize the cables and insert them into the cable slot 7. Connect the main power supply 401 to 380V AC power. The power converter 403 outputs 24V DC power to power the multi-functional control card 404, PLC controller 405 and touch screen. The main power supply 401 outputs 48V DC power to power the straight motor 301 and steering motor 302 through the power distribution box 402.

[0050] S2. Steering action fault detection: Input the target angle value within ±90° through the swing wheel angle parameter setting unit on the touch screen, press and hold the zero point calibration unit, and the PLC controller 405 sends a control signal to the steering motor 302 through the multi-function control card 404 to drive the splitter 3 to complete the steering action. Observe whether the swing wheel of the splitter 3 rotates normally, and check whether the target angle value set on the swing wheel on the touch screen is consistent with the current angle feedback value of the swing wheel. If they are consistent and the swing wheel rotates normally, the steering mechanism is fault-free; otherwise, the steering mechanism is faulty.

[0051] S3. Straight-line operation fault detection: Input the target power value within the range of 0-100 through the roller speed setting parameter unit of the touch operation screen, click the run operation unit, and the PLC controller 405 sends the control signal to the straight-line motor 301 through the multi-function control card 404 to drive the distributor 3 to complete the straight-line operation. Observe whether the roller of the distributor 3 rotates normally, and check whether the roller setting target value on the touch operation screen is consistent with the current speed feedback value of the roller. If they are consistent and the roller rotates normally, the straight-line mechanism is fault-free. Otherwise, it is determined that the straight-line mechanism is faulty. After completing the test, adjust the roller setting speed parameter value to 0 to stop the straight-line motor 301 from running.

[0052] S4. Fault Repair and Retesting: If the test determines that there is a fault in the 3rd component of the splitter, use the repair tools in the drawer to complete the on-site repair. After the repair, repeat steps S2 and S3 until the steering and straight-line movement tests meet the requirements and the fault repair is completed.

[0053] S5. Power off and reset the equipment: After the test or maintenance is completed, disconnect the 380V AC power supply of the main power supply 401, tidy up all the connecting cables, and restore the test device to the initial standby state.

[0054] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A fault detection device for a sorting component of an automated sorting equipment, characterized in that: include: The testing stand (1) has a back plate (2) on one side of its top. A diverter (3) is installed on the top of the test bench (1), and a straight motor (301) and a steering motor (302) are installed on one side of the diverter (3). The testing mechanism (4) includes a main power supply (401) located on the top of the testing bench (1) and a power distribution box (402), a power converter (403), a multi-function control card (404), a PLC controller (405), and a touch screen located on the front side of the back panel (2). The main power supply (401) is electrically connected to the power converter (403) and the power distribution box (402). The power converter (403) is electrically connected to the multi-function control card (404), the PLC controller (405), and the touch screen. The power distribution box (402) is electrically connected to the straight motor (301) and the steering motor (302). The PLC controller (405) and the multi-function control card (404) are connected via a data cable signal.

2. The fault detection device for the diversion component of an automated sorting equipment according to claim 1, characterized in that: The input terminal of the main power supply (401) is connected to 380V AC power to the input terminal of the power converter (403). The power converter (403) converts the 380V AC power into 24V DC power to power the multi-function control card (404), PLC controller (405), and touch screen. The main power supply (401) outputs 48V DC power, which is supplied to the straight motor (301) and the steering motor (302) via the power distribution box (402).

3. The fault detection device for the diversion component of an automated sorting equipment according to claim 1, characterized in that: The touch screen's interactive interface includes a parameter display unit for the balance wheel's set angle, current balance wheel angle, set roller speed, and current roller speed, as well as an operation control unit for zero-point calibration, return, and operation. The touch screen is bidirectionally connected to the PLC controller (405) via signal transmission.

4. The fault detection device for the diversion component of an automated sorting equipment according to claim 1, characterized in that: The front side of the testing stand (1) is provided with multiple tool storage boxes (5) arranged vertically. The tool storage boxes (5) are pull-out structures and have several partitioned chambers inside for classifying and storing maintenance tools.

5. A fault detection device for a diversion component of an automated sorting equipment according to claim 1, characterized in that: The back plate (2) of the test bench (1) is equipped with a cable tray (6) on the front side. The cable tray (6) has several cable slots (7) for combing and fixing cables.

6. A fault detection device for a diversion component of an automated sorting equipment according to claim 5, characterized in that: A support frame (8) is also installed on the front side of the back plate (2). The support frame (8) is located above the wiring frame (6). The PLC controller (405) and the touch screen are both connected to the support frame (8).

7. The fault detection device for the diversion component of an automated sorting equipment according to claim 1, characterized in that: The PLC controller (405) pre-stores an offline splitter (3) control system based on the TIA Portal V16 ladder diagram. The offline splitter (3) control system supports independent parameter setting and operation testing of the splitter (3)'s steering and linear actions.

8. A fault detection device for a diversion component of an automated sorting equipment according to claim 7, characterized in that: The offline splitter (3) control system supports inputting any angle value within the range of ±90° in the swing wheel setting angle parameter unit and any power value within the range of 0-100 in the roller setting speed parameter unit.

9. A detection method for a fault detection device for a diversion component of an automated sorting equipment according to any one of claims 1-8, characterized in that: Includes the following steps: S1. Equipment connection and power supply: Place the splitter (3) on the top of the counter and complete the electrical connection of the main power supply (401), power converter (403), power distribution box (402) with the splitter (3), straight motor (301), steering motor (302) and detection mechanism (4). Organize the cables and insert them into the cable slot (7). Connect the main power supply (401) to 380V AC power. The power converter (403) outputs 24V DC power to power the multi-function control card (404), PLC controller (405) and touch screen. The main power supply (401) outputs 48V DC power through the power distribution box (402) to power the straight motor (301) and steering motor (302). S2, Steering action fault detection: Input the target angle value within ±90° through the swing wheel setting angle parameter unit on the touch operation screen, press and hold the zero point calibration operation unit, and the PLC controller (405) sends the control signal to the steering motor (302) through the multi-function control card (404) to drive the splitter (3) to complete the steering action. Observe whether the swing wheel of the splitter (3) rotates normally, and check whether the target angle setting value of the swing wheel on the touch operation screen is consistent with the current angle feedback value of the swing wheel. If they are consistent and the swing wheel rotates normally, the steering mechanism is fault-free; otherwise, the steering mechanism is faulty. S3, Straight-line operation fault detection: Input the target power value in the range of 0-100 through the roller speed setting parameter unit of the touch operation screen, click the run operation unit, the PLC controller (405) sends the control signal to the straight motor (301) through the multi-function control card (404), drive the splitter (3) to complete the straight-line operation, observe whether the roller of the splitter (3) rotates normally, and check whether the roller setting speed target value on the touch operation screen is consistent with the current speed feedback value of the roller. If they are consistent and the roller rotates normally, the straight-line mechanism is fault-free. Otherwise, the straight-line mechanism is faulty. After the test is completed, adjust the roller setting speed parameter value to 0 to stop the straight motor (301) from running. S4. Fault repair and retest: If the test determines that the splitter (3) component is faulty, use the repair tools in the drawer to complete the on-site repair. After the repair, repeat steps S2 and S3 until the steering and straight-line movement tests meet the requirements and the fault repair is completed. S5. Power off and reset the equipment: After the test or maintenance is completed, disconnect the 380V AC power supply of the main power supply (401), organize all the connecting cables, and restore the test device to the initial standby state.

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