Modular quick-change multi-specification barrel type filling integrated system

Abstract

This application relates to the field of control technology for barrel-type container filling equipment, and discloses a modular quick-change multi-specification barrel filling integrated system. This invention acquires observation data related to the quick-change module, barrel posture, and filling execution under the current barrel-change condition. It establishes a constraint mapping relationship based on the quick-change module's assembly identity and structural boundaries, and generates standardized observation results for the barrel-change condition through filling station calibration. Based on these standardized observation results, it generates the barrel opening access window and static filling constraint results. It performs full-depth matching between the filling gun's descent trajectory and the barrel opening access window, generating trajectory entry margin and barrel-change alignment reliability, and outputs filling permission results. During the filling process, it generates dynamic alignment disturbance results based on the filling process observation data, updates the dynamic alignment state, and generates filling control commands. This invention can reduce the risks of misalignment, scraping, and liquid splashing caused by concealed misalignment after switching between multiple barrel specifications.

Description

Technical Field

[0001] This application relates to the field of control technology for barrel-type container filling equipment, and in particular to a modular quick-change multi-specification barrel-type filling integrated system. Background Technology

[0002] Barrel-type filling machines are widely used in the quantitative filling production of products such as daily chemical liquids, lubricating oils, coatings, adhesives, food raw materials, and chemical liquids. These production lines typically need to be compatible with barrel-type containers of different capacities, heights, opening positions, and shapes, such as round barrels, square barrels, sloping-shoulder barrels, eccentric-mouth barrels, and thin-walled plastic barrels. To adapt to multi-specification production, existing filling machines are usually equipped with replaceable clamping mechanisms, conveying guides, filling gun assemblies, positioning blocks, and sealing accessories. Specification switching is completed through positioning pins, locking blocks, quick-release interfaces, servo formulas, or manual confirmation. Some equipment also incorporates photoelectric detection, visual recognition, weighing feedback, and filling gun lifting control to determine whether the container is in place, the opening position, and the filling volume meet production requirements. This type of solution can shorten changeover time and reduce manual machine adjustment workload to a certain extent, making it suitable for multi-variety, small-batch, or frequently change-line barrel-type product production scenarios.

[0003] However, in actual operation, the installation of the quick-change module does not directly indicate that the filling station has stable filling conditions. Existing equipment often uses the module locking status, specification formula call results, or barrel opening static identification results as the basis for completing the changeover, lacking a comprehensive verification of the relative relationship between the filling nozzle center, barrel opening actual center, clamping center, conveying reference, and barrel posture. Due to the simultaneous existence of factors such as barrel batch tolerance, barrel opening eccentricity, barrel wall elastic deformation, barrel bottom warping, conveyor belt wear, guide clearance, and clamping mechanism return error, the container may experience hidden deviations after entering the filling station. Even if the barrel opening identification result is qualified before filling, the container may still deviate after the filling gun descends and the seal contacts the barrel opening. As liquid gradually enters the container and high-viscosity materials form an off-center load, the container may still sink, bulge, tilt, or oscillate slightly, disrupting the initial alignment. This can easily lead to problems such as nozzle misalignment, container mouth scraping, liquid splashing, external wall contamination, poor sealing, or machine shutdown and reset. Existing technologies typically improve quick-change structures, visual positioning, conveyor limits, or filling gun lifting actions, but it is still difficult to continuously determine whether the current container type, current posture, and current filling gun trajectory meet the conditions for feasible filling after module switching. As a result, multi-specification container filling machines still rely on manual testing and experience calibration, affecting changeover efficiency, filling stability, and production safety. Summary of the Invention

[0004] This application proposes a modular quick-change multi-specification barrel filling machine integrated system to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, this application adopts the following technical solution: a modular quick-change multi-specification barrel filling machine integrated system, comprising: The standardized observation module for changeover conditions acquires observation data for changeover conditions, establishes a constraint mapping relationship between the assembly identity of the quick-change module and the structural boundary, and converts the observation data to the same filling station coordinate system through filling station calibration to generate standardized observation results for changeover conditions. The barrel opening window generation module determines the usable entry area of ​​the barrel opening from the standardized observation results of the changeover working condition, performs boundary shrinkage according to the comprehensive entry margin required for the filling nozzle to enter, and generates the barrel opening entry window and static filling constraint results by combining the lateral offset compensation caused by the barrel tilt. The replacement permission determination module maps the descent trajectory of the filling gun to the barrel opening plane, compares the descent trajectory of the filling gun with the barrel opening's accessible window along the descent depth to generate the trajectory entry margin, and integrates the quick-change module's assembly consistency and contact disturbance status to generate replacement alignment reliability. Based on the replacement alignment reliability, the module outputs the filling permission result. The dynamic alignment control module acquires the observation data of the filling process after the filling permission result is established. It forms the dynamic alignment disturbance result through geometric offset normalization, load rate deviation normalization and pressure fluctuation deviation normalization. Based on the model change alignment reliability and the dynamic alignment disturbance result, it updates the dynamic alignment state and generates filling control commands.

[0006] Furthermore, after the changeover condition is initiated, the standardized observation module collects observation information on the quick-change module assembly, barrel attitude, and filling execution. The quick-change module assembly observation information is used to characterize the assembly identity and locking status of the filling gun quick-change component, clamping quick-change component and guiding quick-change component; the barrel posture observation information is used to characterize the barrel mouth space status, barrel tilt status and barrel bottom support status; and the filling execution observation information is used to characterize the conveying stop status, clamping execution status and filling gun descent reference. The standardized observation module for changeover conditions associates the three types of observation information according to the same changeover condition identifier to form changeover condition observation data.

[0007] Furthermore, the standardized observation module for changeover conditions determines the filling nozzle entry boundary and sealing contact boundary based on the assembly identity of the filling gun quick-change assembly, the clamping center boundary and clamping return boundary based on the assembly identity of the clamping quick-change assembly, and the conveying guide boundary based on the assembly identity of the guide quick-change assembly. After the locking condition meets the assembly conditions, the filling nozzle entry boundary, sealing contact boundary, clamping center boundary, clamping return boundary, and conveying guide boundary are associated with the changeover condition observation data to form a constraint mapping relationship.

[0008] Furthermore, the standardized observation module for changeover conditions converts the spatial state of the barrel opening, the tilt state of the barrel, the conveying stop state, the clamping execution state, and the lowering reference of the filling gun to the same coordinate system of the filling station based on the reference point of the filling station, the calibration results of the filling gun axis, and the observation calibration results of the barrel opening. Establish the spatial correspondence between the usable entry area of ​​the barrel opening, the lateral compensation direction of the barrel tilt, the offset state of the clamping center, the offset state of the conveying reference, and the descent trajectory of the filling gun in the coordinate system of the filling station, and generate standardized observation results for the changeover condition.

[0009] Furthermore, the barrel opening window generation module determines the usable entry area of ​​the barrel opening based on the standardized observation results of the changeover working condition, and combines the sealing contact boundary, clamping center offset state, clamping return boundary and conveying reference offset state into the basic entry constraint, and uses the filling nozzle entry boundary as the basis for the outer envelope occupancy when the filling nozzle enters the barrel opening. The barrel opening window generation module also forms a lateral offset compensation constraint based on the barrel tilt state and the filling gun descent reference, so that the basic entry constraint, lateral offset compensation constraint and filling nozzle entry boundary work together on the inner boundary of the barrel opening usable entry area to obtain the barrel opening usable window.

[0010] Furthermore, the barrel opening window generation module verifies the full depth retention status of the barrel opening accessible window within the effective descent depth range of the filling gun along the descent direction of the filling gun, and determines whether the barrel opening accessible window retains an entry margin that matches the entry boundary of the filling nozzle. When the access window at the barrel opening is in a state of full depth retention and the access margin meets the requirements for the filling nozzle to enter, a static fillable constraint result is generated. If the access window at the barrel opening is not fully retained, or if the remaining amount does not meet the requirements for the filling nozzle to enter, a position correction requirement or a changeover verification result will be generated.

[0011] Furthermore, the replacement permit determination module divides the filling gun's descent trajectory into multiple trajectory verification positions according to the descent direction, and maps each trajectory verification position to the barrel opening plane; The model change permission determination module determines the remaining entry distance of each trajectory verification position relative to the accessible window at the bucket opening, and determines the minimum value among the remaining entry distances as the trajectory entry margin. When the trajectory entry margin does not meet the entry margin condition, generate a position correction requirement or a change verification result.

[0012] Furthermore, after the trajectory entry margin meets the entry margin condition, the quick-change module generates the quick-change module assembly consistency based on the adaptation relationship between the structural boundary corresponding to the quick-change module and the barrel specification, and generates the contact disturbance state based on the contact feedback deviation and the barrel opening relative to the projection position deviation of the filling gun during the descent process. The replacement permission determination module uses the trajectory entry margin as the geometric entry basis, the quick-change module assembly consistency as the structural adaptation basis, and the contact disturbance state as the stability basis for the descent process. It integrates the credibility of the three types of basis to generate the replacement alignment credibility.

[0013] Furthermore, after the filling permit result is established, the dynamic alignment control module collects the deviation of the barrel opening relative to the projection position of the filling gun, the weighing rate sampling result, and the filling pressure fluctuation sampling result. The dynamic alignment control module performs geometric offset normalization on the deviation of the barrel opening relative to the projection position of the filling gun, generating a geometric offset disturbance term; performs load rate deviation normalization on the deviation of the weighing rate sampling result relative to the reference weighing rate, generating a load disturbance term; and performs pressure fluctuation deviation normalization on the deviation of the filling pressure fluctuation sampling result relative to the reference pressure fluctuation, generating a pressure disturbance term. The dynamic alignment control module integrates geometric offset disturbance terms, load disturbance terms, and pressure disturbance terms to obtain dynamic alignment disturbance results.

[0014] Furthermore, the dynamic alignment control module uses the model change alignment reliability as the initial alignment basis at the start of filling, and updates the initial alignment basis by attenuation based on the dynamic alignment disturbance results to obtain the dynamic alignment state. When the dynamic alignment state meets the conditions for maintaining filling, a maintenance filling command is generated. When the dynamic alignment state does not meet the conditions for maintaining filling and does not meet the conditions for stopping and verifying, a deceleration position correction command is generated. When the dynamic alignment state meets the conditions for stopping and verifying, a stop verification command is generated. The filling conditions and shutdown verification conditions are determined by the operating conditions of the same specification barrel type trial run sample, which have no barrel mouth interference, no liquid splashing, and no shutdown reset.

[0015] The beneficial effects of this invention are as follows: This invention collects observation information on the quick-change module assembly, barrel posture, and filling execution. Based on the assembly identity and structural boundaries of the quick-change module, a constraint mapping relationship is formed. Then, standardized observation results of the changeover condition are generated through filling station calibration. This solves the problem that existing multi-specification barrel filling machines rely solely on locking signals, specification formulas, or static barrel opening identification results to determine the completion of the changeover after mechanical quick-change, making it difficult to simultaneously reflect the actual posture of the quick-change module, barrel, and the spatial relationship of the filling execution mechanism. This process unifies the structural boundaries of the quick-change module, barrel posture, and filling execution benchmark, and also reduces the hidden misalignment caused by module assembly gaps, clamping return strokes, conveying stop deviations, and inconsistent filling gun benchmarks.

[0016] This invention generates an accessible window for the barrel opening based on standardized observation results of the changeover working conditions, and performs full-depth matching between the descent trajectory of the filling gun and the accessible window to generate a trajectory entry margin. Then, it combines the assembly consistency of the quick-change module and the contact disturbance state to generate the changeover alignment reliability. This solves the problem that existing equipment only uses the center point of the barrel opening or the theoretical barrel size as the basis for the filling gun entry, making it difficult to determine whether the filling nozzle always maintains a safe entry margin during the descent process. This process transforms the barrel opening boundary, the outer envelope of the filling nozzle, the sealing contact, the clamping offset, the conveying deviation, and the barrel tilt into the basis for filling permission, and also reduces the risk of filling nozzle misalignment, barrel opening scraping, and filling interruption.

[0017] This invention continuously acquires observation data of the filling process after the filling permit result is established. It normalizes and fuses the deviation of the barrel opening relative to the projection position of the filling gun, the weighing rate deviation, and the filling pressure fluctuation deviation to generate a dynamic alignment disturbance result. Based on the alignment reliability of the model change, the dynamic alignment state is updated, and filling maintenance instructions, deceleration position correction instructions, or shutdown verification instructions are generated. This solves the problem that existing equipment performs filling according to a fixed trajectory after completing a positioning before filling, which is difficult to deal with the failure of the initial alignment relationship caused by barrel sinking, bulging, tilting, off-center loading, or limited filling nozzle outlet. This process can continuously verify the degree of alignment relationship maintenance during the filling process and reduce the risk of liquid splashing, barrel mouth contamination, and abnormal shutdown. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort: Figure 1 This is a system framework diagram of the present invention; Figure 2 This is a flowchart of the barrel opening window generation module of the present invention. Detailed Implementation

[0019] 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.

[0020] like Figure 1 and Figure 2As shown, this invention discloses a modular quick-change multi-specification barrel filling machine integrated system, including: a standard observation module for changeover conditions, a barrel opening window generation module, a changeover permission determination module, and a dynamic alignment control module.

[0021] In one implementation, the model changeover condition standardization observation module is used to acquire model changeover condition observation data under the current model changeover condition, form a constraint mapping relationship based on the assembly identity of the quick-change module and the structural boundary, and convert the observation data to the same filling station coordinate system through filling station calibration to generate model changeover condition standardization observation results. The purpose of this module is to convert the quick-change module assembly state, barrel posture and filling execution reference into spatial constraint results under the same filling station coordinate system, so as to provide a data basis for the subsequent generation of the barrel opening access window.

[0022] Once the current changeover condition is initiated, the standardized observation module for the changeover condition collects observation information on the quick-change module assembly, barrel posture, and filling execution. The quick-change module assembly observation information is used to characterize the assembly status and locking position of the filling gun quick-change assembly, clamping quick-change assembly, and guiding quick-change assembly. The barrel posture observation information is used to characterize the barrel opening space status, barrel tilt status, and barrel bottom support status. The filling execution observation information is used to characterize the conveying stop status, clamping execution status, and filling gun descent reference. The standardized observation module for the changeover condition associates the three types of observation information with the same changeover condition identifier to form changeover condition observation data. The changeover condition identifier is jointly determined by the current barrel specification, the current quick-change module combination, the current production batch, and the current filling station number, thus binding observation information from different sources to the same changeover condition.

[0023] In the quick-change module assembly observation information, the assembly identity is obtained through module code, radio frequency identification tag, mechanical limit code, connector identification signal or control system specification number; the locking status is obtained through locking pin position signal, clamping cylinder position signal, quick-change seat contact switch signal or servo locking feedback signal. The assembly identity is used to confirm the current quick-change module combination, and the locking status is used to confirm whether the current quick-change module combination has the prerequisites for entering the structural boundary mapping.

[0024] The standardized observation module for changeover conditions determines the nozzle entry boundary and sealing contact boundary based on the assembly identity of the filling gun quick-change assembly, the clamping center boundary and clamping return boundary based on the assembly identity of the clamping quick-change assembly, and the conveying guide boundary based on the assembly identity of the guide quick-change assembly. Specifically, the nozzle entry boundary is determined by the maximum outer envelope dimension of the nozzle and the manufacturing tolerance of the nozzle end; the sealing contact boundary is determined by the sealing ring compression stroke, the sealing ring radial extension, and the required pressing allowance for contact with the barrel opening; the clamping center boundary is determined by the clamping claw closure repeatability error, clamping surface wear compensation, and clamping mechanism return error; the clamping return boundary is determined by the clamping mechanism opening and closing return difference, cylinder return error, or servo return error; and the conveying guide boundary is determined by the guide plate installation deviation, conveying stop repeatability error, and the swing clearance of the barrel within the guide components. Through this process, the assembly identity of the quick-change module is transformed into a structural boundary participating in the barrel opening entry space judgment.

[0025] The values ​​of the structural boundaries are determined by the equipment factory inspection records, on-site installation calibration records, and current barrel type trial operation samples. For plastic, metal, or composite barrels with a volume of 10L to 30L, the filling gun repeat positioning boundary is 0.2mm to 1.0mm, the clamping return boundary is 0.5mm to 2.0mm, and the conveying guide boundary is 0.5mm to 3.0mm. For barrels with a volume of 50L or more, or for soft barrels where the barrel wall rigidity causes a measurable offset in the barrel opening position after clamping, the clamping return boundary and the conveying guide boundary are 2.0mm to 5.0mm. The value range is determined based on the filling gun no-load descent repeat positioning test, the clamping mechanism opening and closing reset test, the conveying stop repeat positioning test, and the trial operation samples of the same barrel type without barrel opening interference.

[0026] If the on-site calibration result exceeds the aforementioned value range, the standardized observation module for changeover conditions will first output the changeover verification result. After completing the equipment maintenance verification and passing the trial operation verification without barrel mouth interference of the same specification barrel type, the corresponding structural boundary will be updated with the verified on-site calibration result, and the updated structural boundary will be associated with the current changeover condition observation data. If the trial operation verification is not passed, the standardized observation result for changeover conditions will not be generated. Through this process, the structural boundary can be prevented from being infinitely amplified due to equipment wear, installation offset or abnormal calibration results, and a verifiable correspondence between the structural boundary and the subsequent filling safety judgment can be guaranteed.

[0027] After the locking condition meets the assembly conditions, the changeover condition standardization observation module associates the filling nozzle entry boundary, sealing contact boundary, clamping center boundary, clamping return boundary, and conveying guide boundary with the changeover condition observation data to form a constraint mapping relationship. The assembly conditions include the quick-change component assembly identity being identified, the locking condition being established, and the quick-change component having a pre-registered adaptation relationship with the current barrel size. If the assembly identity is missing, the locking condition is not established, or the quick-change component does not have an adaptation relationship with the current barrel size, the changeover condition standardization observation module outputs the changeover verification result and stops generating changeover condition standardization observation results.

[0028] The standardized observation module for changeover conditions converts the observation data to the same filling station coordinate system through filling station calibration. The filling station coordinate system has the center of the filling station as the origin, the conveying direction as the horizontal axis, the vertical conveying direction as the vertical axis, and the lifting direction of the filling gun as the vertical axis. The center of the filling station is determined by the intersection of the theoretical descent axis of the filling gun and the positioning plane of the barrel opening; the conveying direction is determined by the running direction of the conveyor line or the line connecting the conveying positioning blocks; and the lifting direction of the filling gun is determined by the calibration result of the filling gun axis.

[0029] When the spatial state of the barrel opening is represented by image coordinates, contour sensor coordinates, or three-dimensional ranging coordinates, it is first converted to the filling station coordinate system based on the filling station reference point, the filling gun axis calibration results, and the barrel opening observation calibration results. For barrel opening images acquired by the vision camera, the pixel coordinates are converted to millimeter coordinates in the filling station coordinate system through the camera's intrinsic and extrinsic parameters. Then, the usable entry area of ​​the barrel opening and the relative offset state of the barrel opening are determined based on the barrel opening contour fitting results. For data acquired by the three-dimensional ranging sensor, it is converted to the filling station coordinate system through the sensor installation pose calibration results. For the conveying stop state, clamping execution state, and filling gun descent reference, it is converted to the same filling station coordinate system through the position feedback of the corresponding actuator and the filling gun axis calibration results.

[0030] The calibration error for the filling station is between 0.2mm and 1.5mm. This range is determined based on the calibration error observed at the barrel opening, the repeatability error of the camera installation, the calibration error of the filling gun axis, and the repeatability error of the station reference point. The allowance distance is the difference between the minimum inner diameter of the barrel opening and the maximum outer diameter of the filling nozzle. When the allowance distance is no greater than 3mm, it means that the single-sided allowance for the filling nozzle to enter the barrel opening is no greater than 1.5mm. The calibration error for the filling station is between 0.2mm and 0.8mm; when the allowance distance is greater than 3mm... When the filling nozzle enters the barrel opening, it indicates that there is a unilateral geometric margin of more than 1.5mm. The calibration error of the filling station is taken as 0.8mm to 1.5mm. The 3mm dividing value is obtained by converting the unilateral margin between the maximum outer envelope diameter of the filling nozzle and the minimum inner diameter of the barrel opening, and is determined in combination with the filling gun repeatability error, barrel opening observation calibration error and barrel opening interference test run samples. If the calibration error of the filling station does not meet the error range corresponding to the current barrel type, the changeover condition standardization observation module outputs the changeover verification result.

[0031] After coordinate transformation, the standardized observation module for changeover conditions establishes a spatial correspondence between the usable entry area of ​​the barrel opening, the lateral compensation direction of the barrel tilt, the offset state of the clamping center, the offset state of the conveying reference, and the descent trajectory of the filling gun in the filling station coordinate system. The usable entry area of ​​the barrel opening represents the area within the current barrel opening contour that the filling nozzle can enter; the lateral compensation direction of the barrel tilt represents the direction of the barrel opening offset relative to the filling gun axis caused by the barrel tilt during the descent of the filling gun; the offset state of the clamping center represents the offset of the barrel center relative to the theoretical clamping center after the clamping mechanism completes clamping; the offset state of the conveying reference represents the positional deviation of the barrel relative to the conveying guide reference after it stops; and the descent trajectory of the filling gun represents the spatial path of the filling gun in the filling station coordinate system when it descends from the initial position towards the barrel opening.

[0032] The resulting standardized observation results for the changeover condition include the available entry area of ​​the barrel opening, the lateral compensation direction of the barrel tilt, the offset status of the clamping center, the offset status of the conveying reference, the descent trajectory of the filling gun, the entry boundary of the filling nozzle, the sealing contact boundary, the clamping center boundary, the clamping return boundary, and the conveying guide boundary, all associated with the current changeover condition identifier. These standardized observation results serve as input to the barrel opening window generation module, which is used for subsequent boundary shrinkage, lateral offset compensation, and barrel opening access window generation.

[0033] Through this process, the standardized observation module for changeover conditions transforms the assembly identity of the quick-change module into a structural boundary, and unifies the barrel posture and filling execution reference into the filling station coordinate system. This results in standardized observation results for changeover conditions that reflect the spatial constraint relationship between the quick-change module, the actual posture of the barrel, and the filling execution mechanism. These results provide a traceable data basis for the generation of the barrel opening access window, reducing the risk of hidden misalignment caused by barrel eccentricity, clamping return, conveying stop deviation, and inconsistent filling gun descent reference.

[0034] In one implementation, the barrel opening window generation module is used to generate a barrel opening accessible window based on the standardized observation results of the changeover condition and to determine the static filling constraint results. The barrel opening window generation module receives the standardized observation results of the changeover condition output by the standardized observation module of the changeover condition and uses the barrel opening accessible area, barrel tilt lateral compensation direction, clamping center offset state, conveying reference offset state, filling gun descent trajectory, filling nozzle entry boundary, sealing contact boundary, clamping center boundary, clamping return boundary and conveying guide boundary to determine whether the current barrel type retains the space margin required for filling nozzle entry under the current quick change module combination.

[0035] The barrel opening window generation module first determines the usable entry area of ​​the barrel opening based on the standardized observation results of the changeover working condition. The usable entry area of ​​the barrel opening is obtained by converting the spatial state of the barrel opening to the coordinate system of the filling station. It represents the area within the current barrel opening contour that the filling nozzle can enter. The usable entry area of ​​the barrel opening is the actual area obtained by barrel opening observation calibration and barrel opening contour fitting after the current barrel enters the filling station. For circular barrel openings, the actual boundary of the barrel opening is obtained by fitting the barrel opening edge points. For elliptical barrel openings, deformed barrel openings, or eccentric barrel openings, the actual boundary of the barrel opening is determined based on the closed contour of the barrel opening edge points in the coordinate system of the filling station. For isolated edge points that are not continuously connected to the closed contour of the barrel opening, short edge segments formed by reflection obstruction, and edge points that exceed the limit of the barrel opening contour fitting residual, the barrel opening window generation module excludes them from the actual boundary of the barrel opening. If there are obstructions, gaps, or a closed boundary that cannot be formed in the barrel opening contour, the barrel opening window generation module does not generate a barrel opening entry window and outputs the changeover verification result.

[0036] The barrel opening window generation module synthesizes the sealing contact boundary, clamping center offset state, clamping return boundary, and conveying reference offset state into a basic entry constraint, and uses the filling nozzle entry boundary as the basis for the outer envelope occupancy when the filling nozzle enters the barrel opening. The basic entry constraint is used to characterize the space margin that still needs to be reserved from the barrel opening boundary, in addition to the outer envelope occupancy of the filling nozzle itself, without taking into account the lateral compensation for barrel tilt. The filling nozzle entry boundary is used to limit the maximum outer envelope occupancy of the filling nozzle on the barrel opening space. The sealing contact boundary is used to limit the crimping allowance required when the seal contacts the barrel opening. The clamping center offset state is used to characterize the offset of the barrel relative to the theoretical clamping center after it is clamped. The clamping return boundary is used to characterize the barrel position uncertainty caused by the reset error of the clamping mechanism. The conveying reference offset state is used to characterize the offset of the barrel relative to the conveying guide reference after it stops. All of the above boundaries and states are converted into millimeter quantities in the filling station coordinate system and then participate in the formation of the barrel opening access window.

[0037] The basic entry constraint is formed by the sealing contact margin, the filling gun repeat positioning boundary, the clamping offset boundary, the conveying reference offset boundary, and the allowable swing compensation of the barrel. The sealing contact margin is 0.3mm to 1.5mm, which is determined by the radial extension of the sealing ring, the compression stroke of the sealing ring, and the crimping allowance required for barrel mouth contact. When the radial extension of the sealing ring is not greater than 1.0mm and the barrel mouth contact surface is flat, the sealing contact margin is 0.3mm to 0.8mm. When the radial extension of the sealing ring is greater than 1.0mm or there is a manufacturing tolerance on the barrel mouth contact surface, the sealing contact margin is 0.8mm to 1.5mm. The filling gun repeat positioning boundary adopts the filling gun repeat positioning boundary determined in the standardized observation module of the changeover condition. The clamping offset boundary is jointly determined by the clamping center offset state and the clamping return boundary. The conveying reference offset boundary is jointly determined by the conveying reference offset state and the conveying guide boundary.

[0038] The allowable swing compensation for the barrel body is 0.2mm to 2.0mm. This range is determined by the barrel body material, the support status of the barrel bottom, and the lateral shaking amplitude of the barrel opening during trial operation of barrels of the same specification. For metal or composite barrels with a lateral repeated observation deviation of no more than 0.8mm after clamping, the allowable swing compensation is 0.2mm to 0.8mm. For soft plastic barrels with a lateral repeated observation deviation of more than 0.8mm but no more than 2.0mm after clamping, the allowable swing compensation is 0.8mm to 2.0mm. If the lateral repeated observation deviation of the barrel opening after clamping is greater than 2.0mm, the barrel opening window generation module outputs the position correction requirement or the changeover verification result. The value is derived from the repeated observation results of the barrel opening position after clamping and the trial operation sample without barrel opening interference. This is used to retain a safety margin corresponding to the swing of the barrel body in the barrel opening accessible window.

[0039] After the basic entry constraints are formed, the barrel opening window generation module forms a lateral offset compensation constraint based on the barrel tilt state and the filling gun descent reference. The barrel tilt state will cause the filling gun to have a lateral offset relative to the available entry area of ​​the barrel opening during the descent. This lateral offset is related to the filling gun descent depth and the barrel tilt angle. In specific processing, the current descent depth of the filling gun is used as the length reference, and the tangent of the barrel tilt angle is multiplied by the descent depth to obtain the lateral offset compensation amount at the descent depth. Since the unit of descent depth is millimeters and the tangent of the barrel tilt angle is a dimensionless quantity, the unit of the lateral offset compensation amount is still millimeters, which can be combined with the length amount in the basic entry constraints.

[0040] The barrel tilt angle is determined by the deflection angle of the barrel opening plane normal vector relative to the lifting direction of the filling gun, or by taking the arctangent of the ratio of the height difference between the two sides of the barrel's outer contour to the barrel width. For barrels with a volume of 10L to 30L, the barrel tilt angle is 0° to 3°; for barrels with a volume of 50L or more, or barrels with uneven bottom support, the barrel tilt angle is 0° to 2°. This range is determined by the effective insertion depth of the filling gun, the remaining margin of the barrel opening's usable entry area, and trial operation samples of barrels of the same specification without barrel opening interference. When the barrel tilt angle exceeds the allowable tilt angle derived from the barrel opening size, filling nozzle size, foundation entry constraint, and effective insertion depth of the filling gun, the barrel opening window generation module does not use the tilt compensation result and outputs the position correction requirement or the change verification result. This processing is used to prevent the barrel tilt compensation from exceeding the actual space margin of the barrel opening.

[0041] The barrel opening window generation module applies both the basic entry constraint and the lateral offset compensation constraint to the inner boundary of the barrel opening's usable entry area to obtain the barrel opening's usable entry window. Specifically, at each filling nozzle descent depth, the barrel opening window generation module first determines the comprehensive entry margin at that descent depth. The comprehensive entry margin is synthesized from the length margin corresponding to the basic entry constraint and the lateral offset compensation amount at that descent depth. Each item in the basic entry constraint and the lateral offset compensation amount represent the length margin that needs to be reserved from the inner boundary of the barrel opening's usable entry area when the filling nozzle enters the barrel opening. Their physical meaning all point to the distance that the barrel opening boundary shrinks inward. Therefore, they can be synthesized into a comprehensive entry margin under the same filling station coordinate system. Subsequently, using this comprehensive entry margin as the shrinkage distance, the inner boundary of the barrel opening's usable entry area is shrunken. The area retained after shrinkage is the barrel opening's usable entry window at that descent depth. This window represents the spatial area where the filling nozzle can enter the barrel opening without interfering with the barrel opening edge under the current quick-change module combination, the current barrel shape posture, and the current filling execution benchmark.

[0042] If the current changeover condition is denoted as r, and the filling gun descent depth is denoted as z, and z is between 0 and the effective insertion depth of the filling gun, then the comprehensive entry margin is determined according to the following logic: First, the combined result of the sealing contact margin, the filling gun repeat positioning boundary, the clamping offset boundary, the conveying reference offset boundary, and the barrel's allowable swing compensation is taken as the basic entry constraint. Then, the lateral offset compensation amount formed by the descent depth and the tangent of the barrel's tilt angle is superimposed, thus obtaining the comprehensive entry margin at the current descent depth. After that, the shortest inner distance from the candidate entry point in the usable entry area of ​​the barrel opening to the actual boundary of the barrel opening is determined point by point. The distance from the candidate entry point to the actual boundary of the barrel opening is then used. The shortest inner distance is determined because the point where interference first occurs when the filling nozzle enters is on the side with the smallest distance from the candidate entry point to the barrel opening boundary. This distance represents the minimum safety margin corresponding to the candidate entry point. If the shortest inner distance is not less than the combined value of the filling nozzle entry boundary and the current comprehensive entry margin, then the candidate entry point belongs to the barrel opening access window. If the shortest inner distance is less than the combined value of the filling nozzle entry boundary and the current comprehensive entry margin, then the candidate entry point does not belong to the barrel opening access window. This process makes the barrel opening access window simultaneously constrained by the filling nozzle outer envelope, sealing compression, clamping offset, conveying deviation, barrel swing, and barrel tilt.

[0043] The entry boundary of the filling nozzle is determined by the maximum outer radius of the filling nozzle or half of the maximum outer width of the filling nozzle. For circular filling nozzles, the maximum outer radius is used; for non-circular filling nozzles, an equivalent outer radius that can encompass the shape of the nozzle tip is used. The equivalent outer radius is half of the maximum lateral dimension of the nozzle tip shape, in millimeters. This treatment allows circular, elliptical, or sealing flanged filling nozzles to be judged according to a uniform barrel opening entry window.

[0044] To avoid the barrel tilt compensation exceeding the actual space margin at the barrel opening, the barrel opening window generation module also determines the allowable tilt angle based on the minimum available inscribed radius of the current barrel opening's usable entry area. The minimum available inscribed radius is the minimum available inscribed radius that can accommodate candidate entry points in the barrel opening's usable entry area under the current changeover condition. It is calculated from the inscribed circle of the actual barrel opening boundary in the filling station coordinate system or obtained by statistical analysis of the equivalent inscribed distance. The basic entry margin without tilt compensation is synthesized from the sealing contact margin, the filling gun repeat positioning boundary, the clamping offset boundary, the conveying reference offset boundary, and the barrel's allowable swing compensation. It is used to characterize the minimum inward distance that the barrel opening boundary needs to reserve when the barrel tilt is not considered.

[0045] The logic for determining the allowable tilt angle is as follows: Without considering barrel tilt compensation, the minimum radial margin that the barrel opening's usable entry area can provide is the minimum usable inscribed radius minus the filling nozzle entry boundary and the basic entry margin without tilt compensation. This remaining amount represents the maximum lateral distance that can still be consumed by barrel tilting under the current barrel opening size and filling nozzle size. The lateral offset caused by barrel tilting within the effective insertion depth of the filling gun is formed by the effective insertion depth and the tangent of the barrel tilt angle. If this lateral offset does not exceed the maximum lateral distance, the allowable tilt angle can be derived. Therefore, the allowable tilt angle comes from the remaining space at the barrel opening and the effective insertion depth of the filling gun, and is not a preset empirical threshold. If the minimum usable inscribed radius is not greater than the combined value of the filling nozzle entry boundary and the basic entry margin without tilt compensation, it means that the current barrel opening size is insufficient to meet the safe entry conditions without considering barrel tilt. The barrel opening window generation module directly outputs the change verification result. If the barrel tilt angle exceeds the allowable tilt angle, the barrel opening window generation module outputs the position correction requirement or the change verification result.

[0046] The barrel opening window generation module is also used to determine the static fillable constraint results. In specific processing, the barrel opening window generation module sets multiple depth verification positions along the descent direction of the filling gun and generates the barrel opening access window corresponding to each depth verification position. The multiple depth verification positions include at least the position where the filling gun begins to enter the barrel opening, the position where the filling nozzle seal contacts the barrel opening, and the position where the filling gun reaches the effective insertion depth. For the working condition where the effective insertion depth of the filling gun is no more than 80mm, the interval of the depth verification positions is 5mm to 10mm; for the working condition where the effective insertion depth of the filling gun is greater than 80mm, the interval of the depth verification positions is 10mm to 20mm. This interval is determined by the effective insertion depth of the filling gun, the barrel tilt angle, and the descent speed of the filling gun, so that the spatial change of the barrel opening access window during the descent process can be sampled and verified. When the descent speed of the filling gun exceeds the descent speed range corresponding to the sample without barrel opening interference in the trial operation of the same barrel type, the barrel opening window generation module outputs the change verification result and does not continue to generate static fillable constraint results.

[0047] When the accessible window at the barrel opening exists at all depth verification positions, and an entry allowance matching the entry boundary of the filling nozzle is retained at each depth verification position, the barrel opening window generation module determines that the accessible window at the barrel opening has a full depth retention state and generates a static fillable constraint result. The entry allowance is used to represent the remaining safe distance between the entry boundary of the filling nozzle and the accessible window at the barrel opening. The determination of the entry allowance is jointly determined by the maximum outer envelope of the filling nozzle, the calibration error of the filling station, the barrel opening observation error, and the barrel opening interference-free trial operation samples of the same barrel type. For barrel types where the reserved distance between the minimum inner diameter of the barrel opening and the maximum outer envelope diameter of the filling nozzle is no more than 3mm, the retention requirement of the entry allowance is no less than the combined value of the filling station calibration error and the barrel opening observation error. For barrel types where the reserved distance is greater than 3mm, the retention requirement of the entry allowance is determined by the minimum remaining safe distance in the barrel opening interference-free trial operation samples of the same barrel type.

[0048] When the barrel opening access window disappears at any depth verification position, or the access margin does not meet the filling nozzle access requirements, the barrel opening window generation module generates a position correction requirement or a changeover verification result. The position correction requirement is used to instruct subsequent modules to correct the conveying stop position, clamping center position, or filling gun descent reference. The changeover verification result is used to indicate that the current barrel posture, quick change module combination, or filling station calibration result does not meet the conditions for continuing to execute the filling permission judgment. Through this process, the system can identify working conditions such as insufficient barrel opening access window, barrel tilt exceeding the allowable tilt angle, clamping offset exceeding the structural boundary, or conveying reference deviation exceeding the structural boundary before filling begins.

[0049] Compared to the method of positioning the filling gun based solely on the center point of the barrel opening, this implementation method performs boundary shrinkage on the usable entry area of ​​the barrel opening through basic entry constraints and lateral offset compensation constraints. This forms an entry window for the barrel opening that can reflect the effects of the filling nozzle outer envelope, sealing contact, clamping offset, conveying deviation, and barrel tilt. This window provides a spatial boundary for the subsequent changeover permission determination module, enabling the subsequent trajectory entry margin calculation to determine whether the descent trajectory of the filling gun meets the entry requirements within the full depth range. This reduces the risk of filling nozzle misalignment, barrel opening scraping, and liquid splashing caused by concealed misalignment after mechanical quick changeover.

[0050] In one implementation, the replacement permission determination module is used to match the descent trajectory of the filling gun with the barrel opening access window, generate the replacement alignment confidence and output the filling permission result. The replacement permission determination module takes the barrel opening access window and static filling constraint results output by the barrel opening window generation module. Before the filling gun performs filling, it verifies whether the descent trajectory of the filling gun meets the barrel opening access requirements within the effective insertion depth range of the filling gun. The purpose of this module is to make the filling permission result reflect the geometric entry margin, the quick-change module structure adaptation relationship and the contact disturbance state during the descent of the filling gun.

[0051] After the static fillable constraint result is established, the changeover permission determination module obtains the descent trajectory of the filling gun. The descent trajectory of the filling gun is determined by the initial position of the filling gun, the calibration result of the filling gun axis, the descent direction of the filling gun, and the effective insertion depth of the filling gun, and is represented in the filling station coordinate system. The initial position of the filling gun and the descent direction of the filling gun are jointly determined by the position feedback of the servo actuator, the calibration result of the filling gun axis, and the filling station coordinate system. The position feedback of the servo actuator and the calibration of the filling gun axis are known equipment control and calibration methods, which are used in this embodiment to provide input for the trajectory entry margin calculation.

[0052] The replacement permit determination module divides the filling gun's descent trajectory into multiple trajectory verification positions according to the descent direction, and maps each trajectory verification position to the barrel opening plane. The trajectory verification positions correspond to the depth verification positions in the barrel opening window generation module, and include at least the position where the filling gun begins to enter the barrel opening, the position where the filling nozzle seal contacts the barrel opening, and the position where the filling gun reaches the effective insertion depth. For the working condition where the effective insertion depth of the filling gun is no more than 80mm, the interval of the trajectory verification positions is 5mm to 10mm; for the working condition where the effective insertion depth of the filling gun is greater than 80mm, the interval of the trajectory verification positions is 10mm to 20mm. This interval is determined by the effective insertion depth of the filling gun, the descent speed of the filling gun, the barrel tilt angle, and the contraction amplitude of the barrel opening access window in the descent direction, so as to verify the spatial relationship between the filling gun's descent trajectory and the barrel opening access window throughout the entire depth range.

[0053] At each trajectory verification position, the changeover approval module projects the center position of the filling gun onto the barrel opening plane to obtain the projection position of the filling gun. The projection position of the filling gun and the actual boundary of the barrel opening are both in the same filling station coordinate system. The changeover approval module calculates the shortest inner distance from the projection position of the filling gun to the actual boundary of the barrel opening and compares this shortest inner distance with the entry boundary of the filling nozzle and the comprehensive entry margin at the descent depth. The shortest inner distance is used to characterize the minimum available boundary distance corresponding to the projection position of the filling gun in the barrel opening plane; the entry boundary of the filling nozzle is used to characterize the maximum outer envelope of the filling nozzle on the barrel opening space; the comprehensive entry margin is used to characterize the boundary indentation amount that needs to be reserved for sealing contact, positioning error, clamping offset, conveying deviation, barrel swing and barrel tilt. All three are measured in millimeters and can be compared under the same dimension.

[0054] In the specific calculation, the replacement permission determination module generates the remaining entry distance at each trajectory verification position. The remaining entry distance is the shortest inner distance from the projection position of the filling gun to the actual boundary of the barrel opening. The result is the result after subtracting the entry boundary of the filling nozzle and the comprehensive entry margin at the corresponding descent depth. The replacement permission determination module determines the minimum remaining entry distance among all trajectory verification positions as the trajectory entry margin. The basis for this processing is that if there is insufficient remaining entry distance at any depth position during the descent of the filling gun, there will be a risk of barrel opening interference. Therefore, the minimum remaining entry distance among all trajectory verification positions can characterize the most unfavorable entry margin during the descent of the filling gun.

[0055] The trajectory entry margin is measured in millimeters. When the trajectory entry margin is less than 0, it indicates that the filling gun's descent trajectory breaks through the barrel's entry window at at least one trajectory verification position. The replacement permission determination module directly determines that the filling permission result is invalid and outputs the position correction requirement or replacement verification result. When the trajectory entry margin is equal to 0, it indicates that the filling gun's descent trajectory is at the boundary state with the barrel's entry window at the most unfavorable trajectory verification position. Since the geometric entry score is obtained by normalizing the trajectory entry margin and then performing an exponential saturation transformation, the geometric entry score is 0 when the trajectory entry margin is equal to 0, and the replacement alignment confidence is 0. Under the condition that the filling permission threshold is greater than 0, the replacement permission determination module does not output the filling permission result, but outputs the position correction requirement or replacement verification result. When the trajectory entry margin is greater than 0, it indicates that the filling gun's descent trajectory retains an entry margin in geometric space, and the replacement permission determination module continues to generate the quick-change module assembly consistency and contact disturbance state.

[0056] The quick-change module assembly consistency is used to characterize whether the structural boundary of the current quick-change module is compatible with the current barrel size. The changeover permission determination module generates a filling gun module adaptation result based on the compatibility relationship between the structural boundary of the filling gun quick-change component and the current barrel size, generates a clamping module adaptation result based on the compatibility relationship between the structural boundary of the clamping quick-change component and the current barrel size, and generates a guide module adaptation result based on the compatibility relationship between the structural boundary of the guide quick-change component and the current barrel size. The filling gun module adaptation result is determined by the filling nozzle entry boundary, the sealing contact boundary, and the allowable range of the current barrel opening size; clamping module adaptation... The results are determined by the clamping center boundary, the clamping return boundary, and the allowable clamping range of the current barrel shape; the guide module adaptation results are determined by the conveying guide boundary and the allowable range of the current barrel conveying positioning. When the corresponding structural boundary falls within the allowable range of the current barrel specification, the corresponding adaptation result is considered valid; when the corresponding structural boundary does not fall within the allowable range of the current barrel specification, the corresponding adaptation result is considered invalid. When the filling gun module adaptation results, clamping module adaptation results, and guide module adaptation results are all valid, the quick-change module assembly consistency is valid; when any adaptation result is invalid, the quick-change module assembly consistency is invalid, and the changeover verification result is output.

[0057] The contact disturbance state is used to characterize the disturbance caused by barrel mouth interference, abnormal sealing contact, or barrel posture deviation during the descent of the filling gun. The replacement permission determination module obtains the contact feedback deviation and the barrel mouth relative to the projection position deviation of the filling gun within the verification interval from the contact of the filling nozzle seal to the effective insertion depth of the filling gun. The module normalizes the two to form the contact disturbance state. When the verification interval is not entered, the contact feedback deviation is not used as the input of the contact disturbance state.

[0058] The contact feedback deviation is the deviation of the current contact feedback relative to the reference contact feedback, in Newtons. The reference contact feedback is determined by a test run sample with no barrel opening interference under the same barrel type, filling gun quick-change assembly, sealing contact boundary, and descent speed, or by the filling gun contact force calibration results under the standard barrel opening fixture. The inner diameter, barrel opening flatness, and contact boundary of the standard barrel opening fixture are determined by the registered values ​​of the current barrel type and are confirmed by the filling station calibration. The barrel opening relative to the filling gun projection position deviation is the offset of the barrel opening center relative to the filling gun projection position during the filling gun descent, in millimeters. It is calculated from the barrel opening observation calibration results and the filling gun projection position under the same filling station coordinate system.

[0059] The contact feedback deviation is obtained through a contact force sensor, and the maximum absolute deviation between the current contact force sampling result and the reference contact feedback within the same verification interval is taken as the contact feedback deviation. In another embodiment, the contact feedback deviation is obtained through servo motor current feedback or cylinder pressure feedback. First, the current feedback or pressure feedback is converted into an equivalent contact force according to the equipment calibration relationship. Then, the equivalent contact force is compared with the reference contact feedback to obtain the contact feedback deviation. The equivalent contact force is then used for normalization processing to avoid directly mixing the current, pressure and distance quantities.

[0060] The formation process of the contact disturbance state is as follows: First, divide the contact feedback deviation by the combined value of the reference contact feedback and the force reference zero-prevention quantity to obtain the dimensionless force disturbance term; then divide the deviation of the barrel opening relative to the filling gun projection position by the combined value of the trajectory entry margin and the distance zero-prevention quantity to obtain the dimensionless position disturbance term; subsequently, perform weighted fusion of the dimensionless force disturbance term and the dimensionless position disturbance term according to the force disturbance weight and the position disturbance weight to obtain the contact disturbance state. The force reference zero-prevention quantity is taken as the larger of the contact force sensor resolution or the upper limit of the contact feedback sampling noise, ranging from 0.1N to 2N; the distance zero-prevention quantity is taken as the larger of the barrel opening observation calibration resolution or the filling gun position feedback resolution, ranging from 0.01mm to 0.2mm. The force reference zero-prevention quantity and the distance zero-prevention quantity are used to avoid the denominator being 0 and to ensure that the normalization result remains computable when the trajectory entry margin approaches the boundary.

[0061] The sum of the force disturbance weight and the position disturbance weight is 1. When the actual boundary closure recognition condition of the barrel opening is met, the deviation of the barrel opening relative to the projection position of the filling gun is used as direct geometric evidence. The position disturbance weight is 0.6 to 0.8, and the force disturbance weight is 0.2 to 0.4. The actual boundary closure recognition condition of the barrel opening is that the edge points of the barrel opening can form a closed profile, and the barrel opening profile fitting residual meets the barrel opening observation calibration limit. When the actual boundary closure recognition condition of the barrel opening is not met, and the resolution of the contact force sensor is not greater than 2N, the position disturbance weight is 0.4 to 0.6, and the force disturbance weight is 0.4 to 0.6. The specific weights are determined by the corresponding records of the barrel opening relative to the projection position of the filling gun, the contact feedback deviation, and the barrel opening interference event in the trial operation samples of the same barrel type. Through this processing, direct geometric evidence and mechanical contact evidence can participate in the formation of contact disturbance state according to the detection conditions.

[0062] After the trajectory entry margin is greater than 0, the quick-change module assembly consistency is established, and the contact disturbance state is formed, the replacement permission determination module generates the replacement alignment confidence level. The replacement alignment confidence level is jointly determined by the geometric entry basis, the structural adaptation basis, and the descent process stability basis. Among them, the geometric entry basis is obtained by converting the ratio of the trajectory entry margin to the margin normalized scale, and is used to characterize the remaining space of the filling gun descent trajectory relative to the barrel opening's accessible window; the structural adaptation basis is determined by the quick-change module assembly consistency, and is used to characterize whether the current filling gun quick-change component, clamping quick-change component, and guiding quick-change component are compatible with the current barrel type and specification; the descent process stability basis is determined by the contact disturbance state, and is used to characterize whether there is abnormal contact or relative barrel opening offset during the filling gun descent process.

[0063] The margin normalization scale is synthesized from the standard deviation of the filling gun repeatability, the standard deviation of the clamping offset, the standard deviation of the conveying stop deviation, and the margin normalization zero-prevention amount. The standard deviation of the filling gun repeatability is derived from the filling gun no-load descent repeatability test; the standard deviation of the clamping offset is derived from the clamping mechanism opening and closing reset test; the standard deviation of the conveying stop deviation is derived from the conveying stop repeatability test; the margin normalization zero-prevention amount is taken as the larger of the filling gun position feedback resolution, the barrel mouth observation calibration resolution, and the clamping position feedback resolution, ranging from 0.01mm to 0.2mm. Through this processing, the trajectory entry margin is converted into a dimensionless geometric entry basis, avoiding the direct mixing of millimeter quantities with the dimensionless quick-change module assembly consistency or contact disturbance state.

[0064] The alignment confidence level is generated according to the following logic: First, the trajectory entry margin is divided by the margin normalization scale to obtain the dimensionless entry margin; then, the result of exponentially operating the negative value of the dimensionless entry margin by subtracting 1 from the natural exponential function is obtained to obtain the geometric entry score; the assembly consistency of the quick-change module is used as the structural adaptation factor; the negative value of the contact disturbance state is exponentially operated by the natural exponential function to obtain the descent process stability factor; finally, the geometric entry score, structural adaptation factor, and descent process stability factor are fused to obtain the alignment confidence level. The reason for using exponential saturation conversion is that when the trajectory entry margin is near 0, the geometric entry score is more sensitive to its changes; after the trajectory entry margin reaches several times the positioning error, the geometric entry score tends to saturate. The reason for using exponential decay conversion of the contact disturbance state is that the contact disturbance state characterizes the intensity of interference risk, and exponential decay can convert this risk intensity into a descent process stability factor between 0 and 1.

[0065] The value range of the replacement alignment reliability is 0 to 1. When the quick-change module assembly consistency is not met, the structural adaptation factor is 0 and the replacement alignment reliability is 0. When the trajectory entry margin is less than 0, the replacement alignment reliability is not calculated, and the position correction requirement or replacement verification result is directly output. The contact disturbance state participates in the calculation of the descent process stability factor. Through this rule, the replacement alignment reliability includes the trajectory entry margin, module structural adaptation relationship and descent contact disturbance.

[0066] The replacement permission determination module outputs the filling permission result based on the replacement alignment reliability. Specifically, when the barrel opening can be accessed at all trajectory verification positions, the trajectory entry margin is greater than 0, the quick change module assembly consistency is established, and the replacement alignment reliability reaches the filling permission threshold, the filling permission result is output. The filling permission threshold ranges from 0 to 1 and is determined by trial operation samples of barrels of the same specification, quick change components of the same filling gun, quick change components of the same clamping, and quick change components of the same guide.

[0067] When the number of qualified trial operation samples of the same barrel type and quick-change module combination is not less than 20, and the qualified trial operation samples cover the three verification stages of the filling gun starting to enter the barrel mouth, the filling nozzle seal contacting the barrel mouth, and the filling gun reaching the effective insertion depth, the filling permission threshold is taken as the 5th percentile of the changeover alignment reliability among the qualified trial operation samples. The qualified trial operation samples are those without barrel mouth interference, liquid splashing, or shutdown reset. When the number of qualified trial operation samples is less than 20, or the qualified trial operation samples do not cover the three verification stages, the filling permission threshold is taken as the minimum changeover alignment reliability verified by the pre-trial operation, and is updated to the 5th percentile after the subsequent qualified trial operation samples meet the aforementioned quantity and stage coverage conditions. This threshold is derived from the actual interference-free operation results and is used to establish a correspondence between the filling permission results and the barrel mouth interference risk.

[0068] When any filling permission condition is not met, the replacement permission determination module does not output a filling permission result. Instead, it outputs a position correction requirement or a replacement verification result based on the type of condition not met. If the trajectory entry margin is less than or equal to 0, it outputs a filling gun descent reference correction requirement, a conveying stop position correction requirement, or a clamping center position correction requirement. If the quick-change module assembly consistency is not met, it outputs a replacement verification result. If the contact disturbance state exceeds the disturbance boundary corresponding to the trial run sample, it outputs a filling gun descent process verification result. If the replacement alignment reliability does not reach the filling permission threshold, it outputs a position correction requirement or a replacement verification result.

[0069] Through this processing, the replacement permission determination module further transforms the barrel opening access window into a replacement alignment confidence level that can be used for decision-making before filling. Compared with the method of only using visual recognition of the barrel opening center and driving the filling gun to move, this implementation method uses full-depth trajectory verification, quick-change module assembly consistency judgment and contact disturbance state fusion to enable the filling permission result to simultaneously reflect the filling gun descent path, quick-change module structural adaptation and contact stability during the descent process. This reduces the risk of filling nozzle misalignment, barrel opening scraping and filling interruption caused by concealed misalignment after mechanical quick-change.

[0070] In one implementation, the dynamic alignment control module acquires filling process observation data after the filling permission result is established, forms a dynamic alignment disturbance result through geometric offset normalization, load rate deviation normalization, and pressure fluctuation deviation normalization, updates the dynamic alignment state based on the type change alignment reliability and the dynamic alignment disturbance result, and generates filling control commands. The dynamic alignment control module receives the filling permission result and type change alignment reliability output by the type change permission determination module, and continuously judges whether the initial alignment relationship meets the filling execution requirements during the filling process.

[0071] After the filling permit is granted, the dynamic alignment control module initiates filling process observation. The filling process observation data includes the deviation of the barrel opening relative to the projection position of the filling gun, the weighing rate sampling results, the filling pressure fluctuation sampling results, the filling gun contact feedback, and the clamping force sampling results. Among them, the deviation of the barrel opening relative to the projection position of the filling gun serves as direct evidence of geometric misalignment between the barrel opening and the filling gun; the weighing rate sampling results are used to characterize the barrel's load-bearing, sinking, or off-center loading state after the liquid enters the barrel; the filling pressure fluctuation sampling results are used to characterize the state of restricted filling nozzle outlet, abnormal pipeline resistance, or abnormal contact between the filling gun and the barrel opening; the filling gun contact feedback and clamping force sampling results are used to assist in verifying whether the barrel's posture deviates from the state when the filling permit was granted.

[0072] The dynamic alignment control module associates the filling process observation data with the same sampling time. The sampling period is jointly determined by the filling gun descent speed, filling speed, visual frame rate, and weighing sensor response time. In one embodiment, the sampling period is 50ms to 200ms. When the filling gun descent speed does not exceed 50mm / s and the filling speed does not exceed 5kg / s, the sampling period is 100ms to 200ms. When the filling gun descent speed exceeds 50mm / s or the filling speed exceeds 5kg / s, the sampling period is 50ms to 100ms. The sampling period range is determined by the visual recognition delay, the weighing sensor filtering time, and the filling pressure sampling response time to ensure that the barrel opening offset, load response, and pressure response can be collected before the filling control command is generated.

[0073] The dynamic alignment control module first converts the deviation of the barrel opening relative to the filling gun projection position into millimeters through filling station coordinate calibration. Specifically, the dynamic alignment control module acquires the position of the barrel opening center in the filling station coordinate system at each sampling moment and acquires the projection position of the filling gun. The distance between the two in the barrel opening plane is taken as the deviation of the barrel opening relative to the filling gun projection position. The deviation of the barrel opening relative to the filling gun projection position is not directly added to the weighing rate sampling result or the filling pressure fluctuation sampling result. Instead, it is first subjected to geometric offset normalization processing. The geometric offset normalization processing is as follows: the deviation of the barrel opening relative to the filling gun projection position is divided by the combined value of the aforementioned trajectory entry margin and distance zero prevention amount to obtain the geometric offset disturbance term. The distance zero prevention amount is taken as the larger value between the barrel opening observation calibration resolution or the filling gun position feedback resolution, which is between 0.01mm and 0.2mm. This value is based on the visual calibration resolution, the filling gun position feedback resolution, and the barrel opening interference-free trial operation samples of the same barrel type, and is used to avoid the denominator being 0 when the trajectory entry margin approaches the boundary.

[0074] The dynamic alignment control module also generates a load disturbance term based on the weighing rate sampling results. The weighing rate sampling results are obtained by converting the weight difference between adjacent sampling times of the weighing sensor and the sampling period, with the unit being kilograms per second. The reference weighing rate is determined by the current material, current valve opening, current filling speed, and the non-interference test run samples under the current barrel type and specification. In one embodiment, the reference weighing rate is taken as the median of the weighing rates in the non-interference test run samples. The dynamic alignment control module takes the deviation of the weighing rate sampling results relative to the reference weighing rate as the load rate deviation and divides this load rate deviation by... The load disturbance term is obtained by taking the larger value between the reference weighing rate and the zero-prevention value of the weighing rate. The zero-prevention value of the weighing rate is calculated from the resolution of the weighing sensor and the sampling period, and is taken as 0.001 kg / s to 0.05 kg / s. For 10L to 30L barrels, the zero-prevention value of the weighing rate is taken as 0.001 kg / s to 0.02 kg / s. For barrels with a capacity of 50L or more, the zero-prevention value of the weighing rate is taken as 0.01 kg / s to 0.05 kg / s. This range is derived from the minimum resolution of the weighing sensor, the sampling period, and the weighing noise during the filling process, and is used to avoid the normalization result from becoming invalid when the reference weighing rate is close to 0.

[0075] The dynamic alignment control module further generates a pressure disturbance term based on the filling pressure fluctuation sampling results. These sampling results are obtained from pressure sensors at the filling pipeline or filling nozzle inlet, and the unit is Pascal. The filling pressure fluctuation sampling results are formed by the difference between the maximum and minimum pressure values ​​within the same sampling window, or by the deviation amplitude of the current pressure sampling value relative to the steady-state reference pressure. The sampling window consists of 3 to 5 consecutive sampling times, and this value is determined based on the pressure sensor response time and the filling pipeline pulsation cycle to avoid single-point pressure noise directly entering the pressure disturbance term. The reference pressure fluctuation is determined from the non-interference test run samples under the current material, current pipeline status, current valve opening, and current filling speed. In one embodiment... The reference pressure fluctuation is taken as the median of the pressure fluctuation amplitude in the test run samples without barrel opening interference. The dynamic alignment control module takes the deviation of the filling pressure fluctuation sampling result relative to the reference pressure fluctuation as the pressure fluctuation deviation, and divides the pressure fluctuation deviation by the larger value between the reference pressure fluctuation and the pressure zero-prevention amount to obtain the pressure disturbance term. The pressure zero-prevention amount is taken as the larger value between the pressure sensor resolution or the upper limit of the pressure sampling noise, ranging from 10Pa to 1000Pa; it is taken from 10Pa to 200Pa under low-pressure gravity filling conditions and from 200Pa to 1000Pa under pump filling conditions. This range is derived from the pressure sensor resolution, pipeline pulsation noise and test run samples of the same barrel type without barrel opening interference, in order to avoid the normalization result from failing when the reference pressure fluctuation is close to 0.

[0076] After completing the geometric offset normalization, load rate deviation normalization, and pressure fluctuation deviation normalization, the dynamic alignment control module performs perturbation fusion on the geometric offset perturbation, load perturbation, and pressure perturbation terms to generate dynamic alignment perturbation results. The geometric offset perturbation term corresponds to the direct geometric misalignment between the barrel opening and the filling gun, the load perturbation term corresponds to the influence of the barrel's load state on the barrel opening's attitude, and the pressure perturbation term corresponds to the abnormal flow resistance caused by the restricted or abnormal contact of the filling nozzle outlet. All three types of perturbation terms are dimensionless before participating in perturbation fusion to avoid directly adding millimeters, kilograms per second, and Pascals.

[0077] In one implementation, the sum of the geometric offset disturbance weight, load disturbance weight, and pressure disturbance weight is 1. When the actual boundary closure identification condition of the bucket opening is met, the geometric offset disturbance term serves as direct geometric evidence. The geometric offset disturbance weight is 0.5 to 0.7, the load disturbance weight is 0.15 to 0.3, and the pressure disturbance weight is 0.15 to 0.3. The actual boundary closure identification condition of the bucket opening is that the edge points of the bucket opening can form a closed profile, and the fitting residual of the bucket opening profile meets the bucket opening observation calibration limit. When the actual boundary closure identification condition of the bucket opening is not met, and the weighing sensor... When both the pressure sensor and the geometric offset disturbance weights meet the current sampling resolution requirements, the weights for the geometric offset disturbance weights are 0.3 to 0.5, the load disturbance weights are 0.25 to 0.4, and the pressure disturbance weights are 0.25 to 0.4. The specific weights are determined by the corresponding records of the geometric offset disturbance, load disturbance, and pressure disturbance events related to barrel opening interference, liquid splashing, or shutdown reset events in the trial operation samples of barrels of the same specification. This method of setting values ​​is used to ensure that direct geometric evidence is given priority in the dynamic alignment disturbance results, while allowing abnormal barrel load and pressure to participate in control judgment when the barrel opening boundary identification is limited.

[0078] The dynamic alignment disturbance result is a dimensionless result, used to characterize the alignment disturbance intensity at the current sampling moment during the filling process. The dynamic alignment control module uses the replacement alignment confidence level generated by the replacement permission judgment module as the initial alignment basis at the start of filling, and updates the initial alignment basis by attenuation according to the dynamic alignment disturbance result to obtain the dynamic alignment state. Specifically, the process is as follows: the negative value of the dynamic alignment disturbance result is exponentially calculated using the natural exponential function to obtain the disturbance attenuation factor; then the replacement alignment confidence level and the disturbance attenuation factor are fused to obtain the dynamic alignment state at the current sampling moment. The value range of the dynamic alignment state is 0 to 1, used to characterize the degree to which the initial alignment relationship is maintained under the action of barrel sinking, bulging, tilting, off-center loading or vibration during the filling process. The reason for using exponential attenuation is that the dynamic alignment disturbance result corresponds to the interference risk intensity, and exponential attenuation can transform the disturbance intensity into a dynamic alignment state between 0 and 1, and this dynamic alignment state can maintain the same value range as the replacement alignment confidence level.

[0079] The dynamic alignment control module generates filling control commands based on the dynamic alignment status. These commands include a maintain-fill command, a speed reduction position correction command, and a stop verification command. When the dynamic alignment status is not lower than the maintain-fill threshold, the module generates a maintain-fill command to maintain the current filling speed, filling valve opening, and filling gun position. When the dynamic alignment status is lower than the maintain-fill threshold but higher than the stop verification threshold, the module generates a speed reduction position correction command. This command adjusts the filling speed to a low-speed filling setting and corrects the filling gun position or conveyor stop position in the opposite direction of the deviation between the barrel opening and the filling gun's projected position. The filling speed setting is the one verified by the no-liquid-splash test run in the current material formula. Its filling speed is lower than the filling speed used when the filling permission result is established. The single position correction range does not exceed half of the trajectory entry margin and is not less than the filling gun position feedback resolution. The corrected filling gun projection position still needs to meet the barrel opening entry window constraint. If the barrel opening entry window constraint cannot be met after the range correction, the dynamic alignment control module generates a stop verification command. When the dynamic alignment status is not higher than the stop verification threshold, the dynamic alignment control module generates a stop verification command, closes the filling valve, stops the liquid from entering the barrel, maintains the current clamping state, and outputs the change verification result.

[0080] The filling threshold and shutdown verification threshold are determined by trial run samples of the same barrel type. In one embodiment, when the number of qualified trial run samples of the same barrel type and quick-change module combination is not less than 20, and the qualified trial run samples cover the initial filling stage, the stable filling stage, and the stage close to the target filling volume, the filling threshold is taken as the 5th percentile of the dynamic alignment state among the qualified trial run samples. The qualified trial run samples are those without barrel mouth interference, liquid splashing, and shutdown reset. The shutdown verification threshold is determined by offset verification samples of the same barrel type or standard barrel mouth fixture offset verification samples. The offset verification samples are obtained by controlling the deviation of the barrel mouth relative to the projection position of the filling gun, the offset of the clamping center, or the conveying stop deviation. The generated verification samples; when the offset verification sample experiences barrel mouth interference, liquid splashing, or shutdown reset events, the dynamic alignment state corresponding to the valid sampling time before the event occurs is taken as the candidate shutdown verification threshold, and the maximum value among all candidate shutdown verification thresholds is taken as the shutdown verification threshold. If the shutdown verification threshold is not lower than the holding filling threshold, the dynamic alignment control module outputs the sample verification result and re-collects trial run samples or offset verification samples. When the number of qualified trial run samples is less than 20 sets, or the qualified trial run samples do not cover 3 filling stages, the holding filling threshold and shutdown verification threshold are determined by the pre-trial run verification samples and updated after subsequent samples meet the quantity and stage coverage conditions.

[0081] After generating the deceleration position correction command, the dynamic alignment control module continues to collect the filling process observation data at the next sampling time and reconstructs the dynamic alignment disturbance result and dynamic alignment state. If the dynamic alignment state is not lower than the filling maintenance threshold, a filling maintenance command is generated; if the dynamic alignment state is not higher than the shutdown verification threshold, a shutdown verification command is generated. This process enables dynamic offset, load abnormality and pressure abnormality during the filling process to be continuously verified during the filling process, avoiding filling nozzle misalignment, barrel mouth scraping, liquid splashing or filling interruption due to barrel sinking, bulging, tilting, off-center loading or vibration after the initial filling permission is established.

[0082] Through this process, the dynamic alignment control module extends the filling permission result from a one-time judgment before filling to continuous alignment state control during the filling process. Compared with the method of only completing the barrel mouth positioning before filling and then performing filling according to a fixed trajectory, this embodiment generates dynamic alignment disturbance results through geometric offset normalization, load rate deviation normalization, and pressure fluctuation deviation normalization. Based on the dynamic alignment state, it generates filling maintenance commands, deceleration position correction commands, or shutdown verification commands, so that the filling process control can respond to the dynamic misalignment risks caused by barrel load, sinking, off-center loading, and limited filling nozzle outlet.

[0083] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A modular, quick-change, multi-specification barrel filling integrated system, characterized in that, include: The standardized observation module for changeover conditions acquires observation data for changeover conditions, establishes a constraint mapping relationship between the assembly identity of the quick-change module and the structural boundary, and converts the observation data to the same filling station coordinate system through filling station calibration to generate standardized observation results for changeover conditions. The barrel opening window generation module determines the usable entry area of ​​the barrel opening from the standardized observation results of the changeover working condition, performs boundary shrinkage according to the comprehensive entry margin required for the filling nozzle to enter, and generates the barrel opening entry window and static filling constraint results by combining the lateral offset compensation caused by the barrel tilt. The replacement permission determination module maps the descent trajectory of the filling gun to the barrel opening plane, compares the descent trajectory of the filling gun with the barrel opening's accessible window along the descent depth to generate the trajectory entry margin, and integrates the quick-change module's assembly consistency and contact disturbance status to generate replacement alignment reliability. Based on the replacement alignment reliability, the module outputs the filling permission result. The dynamic alignment control module acquires the observation data of the filling process after the filling permission result is established. It forms the dynamic alignment disturbance result through geometric offset normalization, load rate deviation normalization and pressure fluctuation deviation normalization. It updates the dynamic alignment state based on the model change alignment reliability and the dynamic alignment disturbance result and generates filling control commands. After the changeover condition is started, the standardized observation module collects the quick-change module assembly observation information, barrel attitude observation information, and filling execution observation information. The quick-change module assembly observation information is used to characterize the assembly identity and locking status of the filling gun quick-change component, clamping quick-change component and guiding quick-change component; the barrel posture observation information is used to characterize the barrel mouth space status, barrel tilt status and barrel bottom support status; and the filling execution observation information is used to characterize the conveying stop status, clamping execution status and filling gun descent reference. The standardized observation module for changeover conditions associates the three types of observation information according to the same changeover condition identifier to form changeover condition observation data; The standardized observation module for changeover conditions determines the filling nozzle entry boundary and sealing contact boundary based on the assembly identity of the filling gun quick-change assembly, the clamping center boundary and clamping return boundary based on the assembly identity of the clamping quick-change assembly, and the conveying guide boundary based on the assembly identity of the guide quick-change assembly. After the locking condition meets the assembly conditions, the filling nozzle entry boundary, sealing contact boundary, clamping center boundary, clamping return boundary and conveying guide boundary are associated with the changeover condition observation data to form a constraint mapping relationship. The standardized observation module for changeover conditions converts the spatial state of the barrel opening, the tilt state of the barrel, the conveying stop state, the clamping execution state, and the lowering reference of the filling gun to the same coordinate system of the filling station based on the reference point of the filling station, the calibration results of the filling gun axis, and the observation calibration results of the barrel opening. Establish the spatial correspondence between the usable entry area of ​​the barrel opening, the lateral compensation direction of the barrel tilt, the offset state of the clamping center, the offset state of the conveying reference, and the descent trajectory of the filling gun in the coordinate system of the filling station, and generate standardized observation results for the changeover condition.

2. The modular quick-change multi-specification barrel filling integrated system according to claim 1, characterized in that, The barrel opening window generation module determines the usable entry area of ​​the barrel opening based on the standardized observation results of the changeover working condition, and combines the sealing contact boundary, clamping center offset state, clamping return boundary and conveying reference offset state into the basic entry constraint, and uses the filling nozzle entry boundary as the basis for the outer envelope occupancy when the filling nozzle enters the barrel opening. The barrel opening window generation module also forms a lateral offset compensation constraint based on the barrel tilt state and the filling gun descent reference, so that the basic entry constraint, lateral offset compensation constraint and filling nozzle entry boundary work together on the inner boundary of the barrel opening usable entry area to obtain the barrel opening usable window.

3. The modular quick-change multi-specification barrel filling integrated system according to claim 2, characterized in that, The barrel opening window generation module verifies the full depth retention status of the barrel opening access window within the effective descent depth range of the filling gun along the descent direction of the filling gun, and determines whether the barrel opening access window retains an entry margin that matches the entry boundary of the filling nozzle. When the access window at the barrel opening is in a state of full depth retention and the access margin meets the requirements for the filling nozzle to enter, a static fillable constraint result is generated. If the access window at the barrel opening is not fully retained, or if the remaining amount does not meet the requirements for the filling nozzle to enter, a position correction requirement or a changeover verification result will be generated.

4. The modular quick-change multi-specification barrel filling integrated system according to claim 3, characterized in that, The replacement permit determination module divides the filling gun's descent trajectory into multiple trajectory verification positions according to the descent direction, and maps each trajectory verification position to the barrel opening plane; The model change permission determination module determines the remaining entry distance of each trajectory verification position relative to the accessible window at the bucket opening, and determines the minimum value among the remaining entry distances as the trajectory entry margin. When the trajectory entry margin does not meet the entry margin condition, generate a position correction requirement or a change verification result.

5. The modular quick-change multi-specification barrel filling integrated system according to claim 4, characterized in that, After the trajectory entry margin meets the entry margin condition, the quick-change module generates the quick-change module assembly consistency based on the adaptation relationship between the structural boundary corresponding to the quick-change module and the barrel specification, and generates the contact disturbance state based on the contact feedback deviation and the barrel opening relative to the projection position of the filling gun during the descent process. The replacement permission determination module uses the trajectory entry margin as the geometric entry basis, the quick-change module assembly consistency as the structural adaptation basis, and the contact disturbance state as the stability basis for the descent process. It integrates the credibility of the three types of basis to generate the replacement alignment credibility.

6. The modular quick-change multi-specification barrel filling integrated system according to claim 5, characterized in that, After the filling permission result is established, the dynamic alignment control module collects the deviation of the barrel opening relative to the projection position of the filling gun, the weighing rate sampling result, and the filling pressure fluctuation sampling result. The dynamic alignment control module performs geometric offset normalization on the deviation of the barrel opening relative to the projection position of the filling gun, generating a geometric offset disturbance term; performs load rate deviation normalization on the deviation of the weighing rate sampling result relative to the reference weighing rate, generating a load disturbance term; and performs pressure fluctuation deviation normalization on the deviation of the filling pressure fluctuation sampling result relative to the reference pressure fluctuation, generating a pressure disturbance term. The dynamic alignment control module integrates geometric offset disturbance terms, load disturbance terms, and pressure disturbance terms to obtain dynamic alignment disturbance results.

7. The modular quick-change multi-specification barrel filling integrated system according to claim 6, characterized in that, The dynamic alignment control module uses the alignment reliability of the type change as the initial alignment basis at the start of filling, and updates the initial alignment basis by attenuation according to the dynamic alignment disturbance results to obtain the dynamic alignment state. When the dynamic alignment state meets the conditions for maintaining filling, a maintenance filling command is generated. When the dynamic alignment state does not meet the conditions for maintaining filling and does not meet the conditions for stopping and verifying, a deceleration position correction command is generated. When the dynamic alignment state meets the conditions for stopping and verifying, a stop verification command is generated. The filling conditions and shutdown verification conditions are determined by the operating conditions of the same specification barrel type trial run sample, which have no barrel mouth interference, no liquid splashing, and no shutdown reset.

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