An automated device for card singulation

Abstract

This application discloses an automated device for card packaging, including a conveying mechanism, a detection mechanism, and a sorting mechanism. The conveying mechanism includes a first conveyor belt and a second conveyor belt. The detection mechanism is used to sort cards into qualified and unqualified types. The sorting mechanism includes an air-jet assembly and a limiting assembly. The air-jet assembly is used to bend the leading end of unqualified cards toward the gap. When the first conveyor belt conveys the leading end of a qualified card to the gap, the air-jet assembly does not jet downwards, allowing the qualified card to cross the gap and move to the second conveyor belt by its own inertia. When the first conveyor belt conveys the leading end of an unqualified card to the gap, the air-jet assembly jets downwards, bending the leading end of the unqualified card toward the gap, and the limiting assembly prevents the rear end of the card from tilting upwards, allowing the unqualified card to enter the gap. This application has the function of sorting and packaging cards at millisecond-level conveying speeds.

Description

Technical Field

[0001] This application relates to the field of printing machinery, and in particular to an automated device for card packaging. Background Technology

[0002] This application is mainly used in the production process of sheet materials such as cigarette boxes, medicine boxes, playing cards, and scratch cards. It uses a vision inspection system to monitor the surface printing quality of cards flowing at high speed on a conveyor belt. It can accurately detect and judge unqualified cards by color difference, missing print, dirt spots, etc. in the millisecond transmission gap, and quickly separate and remove unqualified cards from the good product flow to ensure the quality of the finished products and improve the efficiency of automated production.

[0003] Existing card inspection equipment includes a rejection mechanism located between the first and second conveyor belts. This rejection mechanism mainly consists of a guide plate, a separating plate, an opening / closing actuator, and a solenoid valve. Under normal operating conditions, the guide plate lies flat, connecting the two conveyor belts and allowing cards to pass smoothly. When a misprinted sheet is detected, the system activates the solenoid valve, disengaging the valve stem from the opening / closing actuator. Under the action of springs and other elastic components, the connecting end of the guide plate and the separating plate mechanically tilts upwards. This displacement of the mechanical structure blocks or alters the paper's path, guiding the defective card into the lower guide trough, thus completing the rejection process.

[0004] However, existing technologies have significant drawbacks. The paperboard feeding, separating, and linkage mechanisms of existing card inspection equipment all possess substantial mechanical mass, resulting in response times for the rejection mechanism's start-up, stop, and reset typically ranging from tens to hundreds of milliseconds, exhibiting significant mechanical lag. This makes them unsuitable for the millisecond-level card transfer requirements. How to solve these technical problems is a question that those skilled in the art need to consider. Summary of the Invention

[0005] To address the aforementioned technical problems, this application provides an automated device for card packaging.

[0006] In one embodiment, the automated device for card sorting includes a conveying mechanism, a detection mechanism, and a sieving mechanism. The conveying mechanism includes a first conveyor belt and a second conveyor belt. The first conveyor belt conveys cards to be sieved, and the second conveyor belt conveys sieved cards. The top surfaces of the first and second conveyor belts are on the same horizontal plane, and a gap is provided between them for defective cards to leave the conveying mechanism. The detection mechanism is spaced apart from the first conveyor belt and is used to detect the cards to be sieved, classifying them as either qualified or unqualified. The sieving mechanism includes an air-jet assembly and a limiting assembly. The air-jet assembly is configured to spray air into the gap to bend the leading end of the unqualified card towards the gap. The limiting assembly is spaced above the discharge end of the first conveyor belt to prevent the card from moving upwards. When the first conveyor belt delivers the leading end of a qualified card to the gap, the jet assembly will not jet downwards, allowing the qualified card to cross the gap by its own inertia and move to the second conveyor belt; when the first conveyor belt delivers the leading end of an unqualified card to the gap, the jet assembly jets downwards, causing the leading end of the unqualified card to bend toward the gap, and the limiting assembly prevents the rear end of the card from tilting upwards, allowing the unqualified card to enter the gap.

[0007] Understandably, this application utilizes an air jet assembly in conjunction with a limiting assembly to replace traditional mechanical baffles for screening cards during high-speed transport. Since the inertia of air is much less than that of mechanical linkages, the air jet assembly can respond quickly and precisely to the leading end of the defective card after the detection mechanism issues a command. Combined with the vertical limiting action of the limiting assembly at the rear of the card, the lever principle causes the defective card to tilt rapidly into the gap using the gap edge as a fulcrum and fall, while the qualified card smoothly crosses the gap unaffected by airflow. This solution resolves the contradiction of mechanical lag in adapting to millisecond-level high-speed transport, improving the synchronization rate of the screening action and the system throughput.

[0008] In one embodiment, the limiting component includes a limiting belt and multiple rotating wheels. The multiple rotating wheels are driven to rotate in the same direction as the conveying direction of the first conveyor belt. The limiting belt is sleeved on the outer circumferential surface of the multiple rotating wheels and driven to connect with the multiple rotating wheels. The portion of the limiting belt corresponding to the conveying mechanism is horizontally arranged and spaced above the conveying mechanism.

[0009] Understandably, the limiting assembly uses multiple rotating wheels to drive the limiting belt, keeping its linear velocity synchronized with the first conveyor belt. This prevents cards from undergoing abnormal displacement or tilting upwards under airflow pressure. Simultaneously, the limiting assembly utilizes the unidirectional movement of the limiting belt to reduce the risk of scratches caused by friction between the card surface and stationary components, maintaining the stability of the card's rear end at the moment of rejection. The limiting assembly ensures that when a defective card bends downwards, its rear end will not tilt upwards and interfere with the transport of other cards upstream of it in the direction of transport of the first conveyor belt.

[0010] In one embodiment, the height of the limiting component is adjustable in the vertical direction, and the position of the limiting component is adjustable in the width direction of the first conveyor belt, so that the limiting component can be spaced above the center position of the various sizes of cards to be screened.

[0011] Understandably, the adjustable height of the limiting component allows the automated card-packing device to adapt to card types of different thicknesses, ensuring that the limiting component maintains a reasonable critical gap with the card's upper surface. The adjustable position of the limiting component along the width of the first conveyor belt ensures that the limiting pressure point always matches the geometric centerline of cards of different widths, preventing rotational yaw caused by force point offset during air jetting, and improving the versatility of the automated card-packing device for multi-size cards.

[0012] In one embodiment, the jet assembly includes at least two jet elements, which are slidably connected to a limiting assembly. The positions of the at least two jet elements are adjustable along the width direction of the first conveyor belt. The at least two jet elements are spaced apart on both sides of the limiting assembly along the width direction of the first conveyor belt, and the nozzles of the jet elements are positioned towards the gap.

[0013] Understandably, at least two adjustable jet nozzles positioned on either side of the limiting component can optimize the distribution of jet application points based on the card's lateral dimensions. When the nozzles of the two jet nozzles apply pressure to the card's pilot end simultaneously, the support effect provided by the central limiting component reduces card skewing caused by uneven force distribution at a single point, ensuring that cards of different widths maintain a consistent bending amplitude at their pilot ends when entering the gap.

[0014] In one embodiment, the screening mechanism further includes a guiding component, which is built into the gap. The guiding component includes at least two guiding rollers, both of which are perpendicular to the conveying direction of the first conveyor belt. The at least two guiding rollers are spaced apart, and the tops of the at least two guiding rollers are on the same horizontal plane as the top surface of the first conveyor belt. The at least two guiding rollers are driven to rotate, and the rotation direction is the same as the conveying direction of the conveying mechanism. A gap is left between the guiding roller closer to the first conveyor belt and the first conveyor belt, and the gap is used for unqualified cards to leave the conveying mechanism.

[0015] Understandably, the guiding assembly, by configuring at least two driven rotating guide rollers in the gap, not only serves as auxiliary support in the vertical direction for qualified cards crossing the gap, reducing the risk of collision caused by the cards sagging due to their own weight, but also, in the horizontal gap, the rotating guide rollers generate an auxiliary force downstream in the conveying process. The curved surface of the guide rollers facilitates guiding unqualified cards into the gap.

[0016] In one embodiment, the automated device for card sorting further includes a control mechanism and a counting mechanism; wherein, the counting mechanism is spaced apart from the second conveyor belt, and the counting mechanism includes a first image acquisition unit, a counting sensor, a reduction wheel, and an alarm device. The counting sensor is spaced above the second conveyor belt and its position is adjustable along the width direction of the second conveyor belt; the position of the reduction wheel along the width direction of the second conveyor belt is adjustable, and the height of the reduction wheel along the vertical direction is adjustable. The reduction wheel cooperates with the second conveyor belt to reduce the speed of the cards conveyed from the first conveyor belt to the second conveyor belt; the first image acquisition unit is located downstream of the reduction wheel relative to the conveying direction of the second conveyor belt, and is used to acquire the conveying status of the sieved cards after being decelerated by the reduction wheel; the first image acquisition unit and the counting sensor are respectively communicatively connected to the control mechanism, and the alarm device is electrically connected to the control mechanism.

[0017] Understandably, the reduction gear, by adjusting its height in conjunction with the conveyor belt, generates local damping, allowing for adjustment of the card's conveying speed as needed. This helps mitigate the ghosting problem caused by high-speed transmission in the first image acquisition unit. When the reduction gear slows down the card's conveying speed, the counting sensor, working in conjunction with the first image acquisition unit, more accurately identifies whether overlapping cards are causing congestion on the second conveyor belt. If congestion occurs on the second conveyor belt, an alarm will sound, ensuring smooth card transmission by the conveyor mechanism.

[0018] In one embodiment, the reduction wheel includes a rotating part and a protruding part. The protruding part is a raised structure extending radially outward from the outer side of the rotating part. When a card is conveyed by the second conveyor belt and passes over the bottom of the reduction wheel, it causes the reduction wheel to rotate. By adjusting the conveying speed of the second conveyor belt, the number of cards passing over the bottom of the reduction wheel in one rotation can be determined. The protruding part is used to separate the predetermined number of cards.

[0019] Understandably, by utilizing the specific geometry of the protrusions and rotating parts, the number of cards passing through the reduction wheel can be determined by the cycle of one rotation of the reduction wheel. As the second conveyor belt drives the cards, triggering the passive rotation of the reduction wheel, the protrusions automatically contact the leading edge of the subsequent cards when they return to the bottom of the reduction wheel after one rotation, forming a physical quantity separation position. This realizes the conversion from flow transmission to quantitative assembly and optimizes the preparation process for subsequent sorting and packaging.

[0020] In one embodiment, the conveying mechanism further includes a third conveyor belt disposed at the end of the second conveyor belt away from the first conveyor belt. The automated device for card sorting also includes a sorting mechanism, which further includes an auxiliary conveying component and a support component. The support component is disposed downstream of the counting mechanism relative to the conveying direction of the second conveyor belt. The support component also includes a receiving member and a supporting member. The supporting member is spaced above the second conveyor belt and is driven to abut or separate from the top surface of the second conveyor belt to block or allow cards to continue being conveyed by the second conveyor belt. The receiving member is disposed downstream of the supporting member relative to the second conveyor belt. The auxiliary conveying component is disposed downstream of the supporting member relative to the conveying direction of the second conveyor belt, and the auxiliary conveying component is disposed upstream of the receiving member relative to the conveying direction of the second conveyor belt. The auxiliary conveying component cooperates with the second conveyor belt to convey cards from the second conveyor belt to the third conveyor belt.

[0021] Understandably, the support assembly acts as a buffer node, creating temporary segmentation points through the contact and separation between the support component and the second conveyor belt, guiding groups of cards into the receiving component to form a neat stack. The support assembly, in conjunction with the auxiliary conveying assembly, then pushes and conveys the entire stack of cards, realizing the transformation from single-item card conveying to conveying groups containing a defined number of cards.

[0022] In one embodiment, the automated device for card sorting further includes a packing assembly, which is located downstream of the sorting mechanism relative to the conveying direction of the third conveyor belt. The packing assembly includes a packing component, a pusher plate, and a sensor. The sensor is communicatively connected to the control mechanism, and the packing component is electrically connected to the control mechanism. When the sensor detects that there is a card on the upper surface of the third conveyor belt, the pusher plate is driven to push the card to the location of the packing component, and the packing component packs the card. When the sensor detects that there is no card on the upper surface of the third conveyor belt, the pusher plate does not operate.

[0023] Understandably, by setting up sensors, the pusher only performs the pushing action when the sensor detects that the card has reached the designated packaging position. This helps improve the working efficiency of the automated card packaging device and reduce power consumption. Optimizing the operation sequence through sensor signals avoids ineffective looping and wasted energy in the pusher and packaging components, thus improving the automation level of the automated card packaging device from card screening, rejection, counting to packaging.

[0024] In one embodiment, the detection mechanism includes two sets of detection components. Each set of detection components includes a three-dimensional image acquisition component for detecting unevenness and a two-dimensional image acquisition component for detecting color difference. One set of detection components is spaced apart above the first conveyor belt, with one three-dimensional image acquisition component and one two-dimensional image acquisition component facing the top surface of the first conveyor belt. The surface of the first conveyor belt has several through holes. The other set of detection components is spaced apart below the first conveyor belt, with one three-dimensional image acquisition component and one two-dimensional image acquisition component facing the bottom surface of the first conveyor belt.

[0025] Understandably, the first conveyor belt features through-holes, breaking the physical obstruction of the bottom-view perspective inherent in traditional enclosed conveyors. The 3D image acquisition unit detects subtle surface irregularities on both sides of the cards, such as dents, scratches, and edge deformation. The 2D image acquisition unit identifies the printing color quality on both sides, such as ghosting and ink shift. These two sets of detection components form a multimodal, full-field-of-view monitoring system, providing reliable decision signals based on detailed physical feature interpretation to the upstream millisecond-level pneumatic screening mechanism, thus reducing missed screenings and false positives. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the main conveying mechanism of the automated card sorting device provided in the embodiments of this application.

[0027] Figure 2 This is a schematic diagram illustrating the main packaging components of the automated card packaging device provided in this application embodiment.

[0028] Figure 3 yes Figure 1 A magnified view of part A in the middle.

[0029] Figure 4 This is a cross-sectional view of the testing organization provided in the embodiments of this application.

[0030] Figure 5 This is a schematic diagram of the screening mechanism provided in the embodiments of this application.

[0031] Figure 6 This is a schematic diagram of the reduction gear provided in an embodiment of this application.

[0032] Figure 7 yes Figure 1 A magnified view of part B in the middle section.

[0033] Explanation of reference numerals in the attached figures: 1. Conveying mechanism; 11. First conveyor belt; 111. Through hole; 12. Second conveyor belt; 13. Third conveyor belt; 2. Gap; 21. Slit; 3. Detection mechanism; 31. Detection component; 311. Three-dimensional image acquisition component; 312. Two-dimensional image acquisition component; 4. Screening mechanism; 41. Air jet assembly; 411. Air jet component; 4111. Nozzle; 412. Second vertical adjustment component; 413. Second horizontal adjustment component; 42. Limiting component; 421. Limiting belt; 422. Rotary wheel; 423. First vertical adjustment component; 424. First horizontal adjustment component; 43. Guiding assembly; 431. Guiding roller; 5. Control mechanism; 6. Counting mechanism; 61. First image acquisition unit; 62. Counting sensor; 63. Reduction wheel; 631. Rotating part; 632. Protrusion; 64. Alarm unit; 65. Third vertical adjustment unit; 66. Third horizontal adjustment unit; 67. Rotation adjustment unit; 7. Sorting mechanism; 71. Auxiliary conveying assembly; 72. Support assembly; 721. Receiving part; 722. Support part; 73. Support frame; 8. Packaging assembly; 81. Packaging part; 82. Push plate; 83. Sensor; 84. Three-axis robotic arm. Detailed Implementation

[0034] The following is in conjunction with the appendix Figure 1 To be continued Figure 7 This application will be described in further detail below.

[0035] In one embodiment, the automated device for card sorting includes a conveying mechanism 1, a detection mechanism 3, and a sieving mechanism 4. The conveying mechanism 1 includes a first conveyor belt 11 and a second conveyor belt 12. The first conveyor belt 11 conveys cards to be sieved, and the second conveyor belt 12 conveys sieved cards. The top surfaces of the first conveyor belt 11 and the second conveyor belt 12 are on the same horizontal plane, and a gap 2 is provided between the first conveyor belt 11 and the second conveyor belt 12 for unqualified cards to leave the conveying mechanism 1. The detection mechanism 3 is spaced apart from the first conveyor belt 11 and is used to detect the cards to be sieved, classifying them as qualified or unqualified. The sieving mechanism 4 includes an air jet assembly 41 and a limiting assembly 42. The air jet assembly 41 is configured to jet air towards the gap 2 to bend the leading end of unqualified cards towards the gap 2. The limiting assembly 42 is spaced apart above the unloading end of the first conveyor belt 11 to prevent the cards from moving upwards. When the first conveyor belt 11 conveys the leading end of a qualified card to the position corresponding to gap 2, the jet assembly 41 will not jet downwards, allowing the qualified card to cross gap 2 by its own inertia and move to the second conveyor belt 12; when the first conveyor belt 11 conveys the leading end of an unqualified card to the position corresponding to gap 2, the jet assembly 41 jets downwards, causing the leading end of the unqualified card to bend toward gap 2, and the limiting assembly 42 prevents the rear end of the card from tilting upwards, allowing the unqualified card to enter gap 2.

[0036] In this embodiment, refer to Figure 1 and Figure 3 Both the first conveyor belt 11 and the second conveyor belt 12 can be annular conveyor belts, and the conveying directions of the first conveyor belt 11 and the second conveyor belt 12 are the same. The detection mechanism 3 is spaced above the first conveyor belt 11, and the screening mechanism 4 is spaced above the conveying mechanism 1 and spaced downstream of the detection mechanism 3 in the conveying direction of the first conveyor belt 11. The limiting components 42 are spaced above the discharge end of the first conveyor belt 11, the gap 2, and the second conveyor belt 12.

[0037] This application utilizes an air jet assembly 41 in conjunction with a limiting assembly 42 to replace the traditional mechanical baffle for screening cards during high-speed transport. Since the inertia of air is much less than that of mechanical linkages, the air jet assembly 41 can quickly respond and precisely act on the leading end of the defective card after the detection mechanism 3 issues a command. Combined with the vertical limiting effect of the limiting assembly 42 at the rear end of the card, the lever principle is used to cause the defective card to quickly tilt and fall into the gap 2 with the edge of the gap 2 as a fulcrum, while the qualified card smoothly crosses the gap 2 without airflow interference. This solution solves the contradiction that the lag in mechanical action cannot adapt to millisecond-level high-speed transport, improving the synchronization rate of the screening action and the system throughput.

[0038] In one embodiment, the detection mechanism 3 includes two sets of detection components 31. Each set of detection components 31 includes a three-dimensional image acquisition component 311 for detecting unevenness and a two-dimensional image acquisition component 312 for detecting color difference. One set of detection components 31 is spaced above the first conveyor belt 11, with one three-dimensional image acquisition component 311 and one two-dimensional image acquisition component 312 facing the top surface of the first conveyor belt 11. The surface of the first conveyor belt 11 is provided with a plurality of through holes 111. The other set of detection components 31 is spaced below the first conveyor belt 11, with one three-dimensional image acquisition component 311 and one two-dimensional image acquisition component 312 facing the bottom surface of the first conveyor belt 11.

[0039] In this embodiment, refer to Figure 1 , Figure 3 and Figure 4The surface of the first conveyor belt 11 has several through holes 111, through which the detection component 31 detects the lower surface of the card. The detection mechanism 3 includes two sets of detection components 31. The first set of detection components 31 is located in the middle of the annular first conveyor belt 11 and faces the lower surface of the top surface of the first conveyor belt 11. The first three-dimensional image acquisition unit 311 is located downstream of the first two-dimensional image acquisition unit 312 relative to the conveying direction of the first conveyor belt 11. The second set of detection components 31 is located above the top surface of the annular first conveyor belt 11 and faces the upper surface of the top surface of the first conveyor belt 11. The second set of detection components 31 is located downstream of the first set of detection components 31 relative to the conveying direction of the first conveyor belt 11. The second three-dimensional image acquisition unit 311 is located downstream of the second two-dimensional image acquisition unit 312 relative to the conveying direction of the first conveyor belt 11.

[0040] The first conveyor belt 11 has a through hole 111, breaking the physical obstruction of the bottom view from the traditional closed conveyor. The three-dimensional image acquisition unit 311 is used to detect subtle surface unevenness changes on both sides of the card, such as pits, scratches, and edge deformation. The two-dimensional image acquisition unit 312 can identify the printing color quality on both sides, such as ghosting and ink offset. The two sets of detection components 31 form a multimodal full-field-of-view monitoring system, providing reliable decision signals based on detailed physical feature interpretation for the upstream millisecond-level pneumatic screening mechanism, reducing the rate of missed screening and false judgment.

[0041] In one embodiment, the limiting component 42 includes a limiting belt 421 and a plurality of rotating wheels 422. The plurality of rotating wheels 422 are driven to rotate in the same direction as the conveying direction of the first conveyor belt 11. The limiting belt 421 is sleeved on the outer peripheral surface of the plurality of rotating wheels 422 and is driven to connect with the plurality of rotating wheels 422. The portion of the limiting belt 421 corresponding to the conveying mechanism 1 is horizontally arranged and spaced above the conveying mechanism 1.

[0042] In this embodiment, refer to Figure 1 and Figure 5 The limiting belt 421 is a ring-shaped conveyor belt and is vertically arranged. The conveying direction of the portion of the limiting belt 421 corresponding to the conveying mechanism 1 is the same as the conveying direction of the first conveyor belt 11, and the linear velocity of the limiting belt 421 is equal to the linear velocity of the first conveyor belt 11. Some rollers 422 are spaced apart along the conveying direction of the first conveyor belt 11, and the remaining rollers 422 are arranged above the partial rollers 422. The remaining rollers 422 and the partial rollers 422 cooperate to increase the tension on the surface of the limiting belt 421.

[0043] The limiting component 42 drives the limiting belt 421 through multiple rotating wheels 422 to keep its linear velocity synchronized with the first conveyor belt 11, thereby preventing abnormal displacement or upward tilting of the card under airflow pressure. Simultaneously, the limiting component 42 utilizes the unidirectional movement of the limiting belt 421 to reduce the risk of scratches caused by friction between the card surface and stationary components, maintaining the stability of the card's rear end posture at the moment of rejection. The limiting component 42 ensures that when a defective card bends downwards, its rear end will not tilt upwards and interfere with the transmission of other cards upstream of the first conveyor belt 11 in the transmission direction.

[0044] In one embodiment, the height of the limiting component 42 is adjustable in the vertical direction, and the position of the limiting component 42 is adjustable in the width direction of the first conveyor belt 11, so that the limiting component 42 can be spaced above the center position of the various sizes of cards to be screened.

[0045] In this embodiment, refer to Figure 1 , Figure 3 and Figure 5 The limiting component 42 also includes two first vertical adjusting members 423 and one first horizontal adjusting member 424. The two first vertical adjusting members 423 are disposed on both sides of the first conveyor belt 11 along the width direction, and the first horizontal adjusting member 424 is located between the two first vertical adjusting members 423. The two first vertical adjusting members 423 and the first horizontal adjusting member 424 are located on the same vertical plane.

[0046] The height adjustability of the limiting component 42 allows the automated card-packing device to adapt to card types of different thicknesses, ensuring that the limiting component 42 maintains a reasonable critical gap 2 with the upper surface of the card. The adjustable position of the limiting component 42 along the width direction of the first conveyor belt 11 ensures that the limiting pressure point always matches the geometric center line of cards of different widths, avoiding rotational yaw caused by the offset of the force point during air jetting, and improving the versatility of the automated card-packing device for multi-size cards.

[0047] In one embodiment, the jet assembly 41 includes at least two jet elements 411, which are slidably connected to the limiting assembly 42. The positions of the at least two jet elements 411 along the width direction of the first conveyor belt 11 are adjustable. The at least two jet elements 411 are spaced apart on both sides of the limiting assembly 42 along the width direction of the first conveyor belt 11, and the nozzles 4111 of the jet elements 411 are arranged toward the gap 2.

[0048] In this embodiment, refer to Figure 1 , Figure 3 and Figure 5The jet assembly 41 also includes two second vertical adjusting members 412 and two second horizontal adjusting members 413. The two second vertical adjusting members 412 are disposed on both sides of the first conveyor belt 11 along its width direction, and the two second horizontal adjusting members 413 are located between the two second vertical adjusting members 412. The two second vertical adjusting members 412 and the two second horizontal adjusting members 413 are located on the same vertical plane, and the two second horizontal adjusting members 413 are respectively connected to two nozzles 4111. The two second horizontal adjusting members 413 are located downstream of the first horizontal adjusting member 424 relative to the conveying direction of the first conveyor belt 11.

[0049] At least two adjustable jet nozzles 411, distributed on both sides of the limiting component 42, can optimize the distribution of jet application points according to the lateral dimensions of the card. When the nozzles 4111 of the two jet nozzles 411 apply pressure to the leading end of the card simultaneously, the support effect formed by the limiting component 42 in the middle reduces the card skewing caused by uneven force at a single point, ensuring that cards of different widths can maintain a consistent bending amplitude of the leading end when entering the gap 2.

[0050] In one embodiment, the screening mechanism 4 further includes a guide component 43, which is built into the gap 2. The guide component 43 includes at least two guide rollers 431, which are perpendicular to the conveying direction of the first conveyor belt 11. The at least two guide rollers 431 are spaced apart, and the top of the at least two guide rollers 431 is on the same horizontal plane as the top surface of the first conveyor belt 11. The at least two guide rollers 431 are driven to rotate, and the rotation direction is the same as the conveying direction of the conveying mechanism 1. A gap 21 is left between the guide roller 431 closest to the first conveyor belt 11 and the first conveyor belt 11. The gap 21 is used for unqualified cards to leave the conveying mechanism 1.

[0051] In this embodiment, refer to Figure 1 , Figure 3 and Figure 5 The guiding assembly 43 includes two guiding rollers 431, the length of which is equal to the width of the first conveyor belt 11. By configuring at least two driven rotating guiding rollers 431 in the gap 2, the guiding assembly 43 not only serves as auxiliary support in the vertical direction for qualified cards crossing the gap 2, reducing the risk of collisions caused by the cards sagging under their own weight, but also, at the horizontal gap 21, the rotating guiding rollers 431 generate an auxiliary force downstream in the conveying process. The curved surface of the guiding rollers 431 facilitates guiding unqualified cards into the gap 21.

[0052] In one embodiment, the automated device for card sorting further includes a control mechanism 5 and a counting mechanism 6. The counting mechanism 6 is spaced apart from the second conveyor belt 12. The counting mechanism 6 includes a first image acquisition unit 61, a counting sensor 62, a reduction wheel 63, and an alarm unit 64. The counting sensor 62 is spaced above the second conveyor belt 12 and its position is adjustable along the width direction of the second conveyor belt 12. The reduction wheel 63 is adjustable in position along the width direction of the second conveyor belt 12 and its height is adjustable in the vertical direction. The reduction wheel 63 cooperates with the second conveyor belt 12 to reduce the speed of the cards conveyed from the first conveyor belt 11 to the second conveyor belt 12. The first image acquisition unit 61 is located downstream of the reduction wheel 63 relative to the conveying direction of the second conveyor belt 12 and is used to acquire the conveying status of the sieved cards after being decelerated by the reduction wheel 63. The first image acquisition unit 61 and the counting sensor 62 are communicatively connected to the control mechanism 5, and the alarm unit 64 is electrically connected to the control mechanism 5.

[0053] In this embodiment, refer to Figure 1 , Figure 2 , Figure 3 and Figure 6 The control mechanism 5 can employ a processor such as a computer. The counting mechanism 6 also includes two third vertical adjustment members 65, one third horizontal adjustment member 66, and one rotary adjustment member 67. The two third vertical adjustment members 65 are located on both sides of the second conveyor belt 12 along its width direction, and the third horizontal adjustment member 66 is located between the two third vertical adjustment members 65. The two third vertical adjustment members 65 and the third horizontal adjustment member 66 are located on the same vertical plane, and the third horizontal adjustment member 66 is connected to the counting sensor 62. The third horizontal adjustment member 66 is located downstream of the second horizontal adjustment member 413 relative to the conveying direction of the first conveyor belt 11. The rotary adjustment member 67 is located downstream of the third vertical adjustment member 65 relative to the conveying direction of the second conveyor belt 12. The rotary adjustment member 67 is connected to the reduction wheel 63 and the alarm member 64, respectively, and is used to adjust the distance of the reduction wheel 63 along the width direction of the second conveyor belt 12. The first image acquisition device 61 can be a camera, and the first image acquisition device 61 and the rotation adjustment device 67 are arranged in the same width direction of the second conveyor belt 12.

[0054] The reduction wheel 63, by adjusting its height in coordination with the conveyor belt, generates local damping, which can adjust the conveying speed of the cards to be detected as needed, thus mitigating the ghosting problem of the first image acquisition unit 61 caused by high-speed transmission. When the reduction wheel 63 reduces the card conveying speed, the counting sensor 62, working in conjunction with the first image acquisition unit 61, more accurately identifies whether overlapping cards are congested on the second conveyor belt 12. If card congestion occurs on the second conveyor belt 12, the alarm unit 64 will issue an alarm signal, ensuring the smooth transmission of cards by the conveyor mechanism 1.

[0055] In one embodiment, the reduction wheel 63 includes a rotating portion 631 and a protrusion 632. The protrusion 632 is a raised structure extending radially outward from the outer side of the rotating portion 631. When a card is conveyed by the second conveyor belt 12 and passes over the bottom of the reduction wheel 63, it causes the reduction wheel 63 to rotate. By adjusting the conveying speed of the second conveyor belt 12, the number of cards passing over the bottom of the reduction wheel 63 in one rotation can be determined. The protrusion 632 is used to separate the predetermined number of cards.

[0056] In this embodiment, refer to Figure 1 and Figure 6 The reduction wheel 63 is driven to rotate in the same direction as the second conveyor belt 12. The reduction wheels 63 are spaced apart above the second conveyor belt 12. The reduction wheel 63 includes a rotating part 631 and a protruding part 632. The rotating part 631 and the protruding part 632 are fixedly connected. The rotating part 631 has a disc-shaped structure, and the protruding part 632 has a curved rod-shaped structure.

[0057] By utilizing the specific geometric mechanism of the protrusion 632 and the rotating part 631, the number of cards passing through the reduction wheel 63 can be determined by the rotation cycle of the reduction wheel 63. As the second conveyor belt 12 drives the cards, triggering the passive rotation of the reduction wheel 63, the protrusion 632 automatically contacts the leading edge of the subsequent card when it rotates back to the bottom of the reduction wheel 63, forming a physical quantity separation position. This realizes the conversion from flow transmission to quantitative assembly and optimizes the preparation process for subsequent sorting and packaging.

[0058] In one embodiment, the conveying mechanism 1 further includes a third conveyor belt 13, which is disposed at the end of the second conveyor belt 12 away from the first conveyor belt 11. The automated device for card sorting also includes a sorting mechanism 7, which further includes an auxiliary conveying component 71 and a support component 72. The support component 72 is disposed downstream of the counting mechanism 6 relative to the conveying direction of the second conveyor belt 12. The support component 72 also includes a receiving member 721 and a support member 722. The support member 722 is spaced above the second conveyor belt 12 and is driven to abut or separate from the top surface of the second conveyor belt 12 to block or allow cards to continue to be conveyed by the second conveyor belt 12. The receiving member 721 is disposed downstream of the support member 722 relative to the second conveyor belt 12. The auxiliary conveying component 71 is located downstream of the support member 722 in the conveying direction of the second conveyor belt 12, and the auxiliary conveying component 71 is located upstream of the receiving member 721 in the conveying direction of the second conveyor belt 12. The auxiliary conveying component 71 cooperates with the second conveyor belt 12 to convey the card from the second conveyor belt 12 to the third conveyor belt 13.

[0059] In this embodiment, refer to Figure 1and Figure 7 The third conveyor belt 13 is a ring conveyor belt, and multiple conveying stations are equally spaced above the corresponding conveying sections of the second conveyor belt 12. Auxiliary conveying components 71 are spaced apart above the unloading end of the second conveyor belt 12. The sorting mechanism 7 also includes two support frames 73, which are located on both sides of the unloading end of the second conveyor belt 12 along its width. The auxiliary conveying components 71 are elastically connected to the two support frames 73, allowing the auxiliary conveying components 71 to adaptively adjust their height in the vertical direction to accommodate cards of different sizes. The auxiliary conveying components 71 cooperate with the second conveyor belt 12 to give the cards the acceleration necessary to be conveyed from the second conveyor belt 12 to the third conveyor belt 13. A support member 722 is located upstream of the auxiliary conveying components 71 relative to the second conveyor belt 12. The support member 722 is a square plate and is vertically arranged. Driven, the support member abuts against or separates from the top surface of the second conveyor belt 12 in the vertical direction. The receiving member 721 can be a brush. When the support member 722 blocks the cards, the receiving member 721 is used to buffer and align the cards that are about to be stacked to form a neat stack.

[0060] The support assembly 72 acts as a buffer node, creating temporary segmentation points through the contact and separation between the support member 722 and the second conveyor belt 12, guiding groups of cards into the receiving member 721 to form a neat stack. The support assembly 72, in conjunction with the auxiliary conveying assembly 71, performs subsequent pushing and conveying of the entire stack of cards, realizing the transformation from single-item card conveying to conveying groups containing a certain number of cards.

[0061] In one embodiment, the automated device for card sorting further includes a packing assembly 8, which is located downstream of the sorting mechanism 7 relative to the conveying direction of the third conveyor belt 13. The packing assembly 8 includes a packing component 81, a pusher plate 82, and a sensor 83. The sensor 83 is communicatively connected to the control mechanism 5, and the packing component 81 is electrically connected to the control mechanism 5. When the sensor 83 senses that there is a card on the upper surface of the third conveyor belt 13, the pusher plate 82 is driven to push the card to the position of the packing component 81, and the packing component 81 packs the card. When the sensor 83 senses that there is no card on the upper surface of the third conveyor belt 13, the pusher plate 82 does not work.

[0062] In this embodiment, refer to Figure 1The packaging assembly 81 can be an automatic packaging machine used to package a predetermined number of cards. A sensor 83 is positioned corresponding to the unloading end of the third conveyor belt 13 and is communicatively connected to the control mechanism 5. The packaging assembly 81 is positioned downstream of the sensor 83 relative to the conveying direction of the third conveyor belt 13 and is electrically connected to the control mechanism 5. When the sensor 83 senses that a predetermined number of card sets are placed on the third conveyor belt 13 at the corresponding conveying station, the pusher plate 82 pushes the predetermined number of card sets away from the third conveyor belt 13; when the sensor 83 senses that no predetermined number of card sets are placed on the third conveyor belt 13 at the corresponding conveying station, the pusher plate 82 does not operate. The packaging assembly 8 also includes a three-axis robotic arm 84, which grips the predetermined number of card sets leaving the third conveyor belt 13 and transfers them to the designated placement area.

[0063] By configuring sensor 83, the pusher plate 82 only performs the pushing action when sensor 83 detects that the card has reached the designated packaging position. This improves the working efficiency of the automated card packaging device and reduces power consumption. The operation timing is optimized through the sensor 83 signal, avoiding unnecessary cycle waste of the pusher plate 82 and packaging component 8, and improving the automation level of the automated card packaging device from card screening, rejection, counting to packaging.

[0064] The implementation principle of this application embodiment is as follows: The cards to be packaged are conveyed on the first conveyor belt 11. When passing the detection mechanism 3, the upper and lower image acquisition units detect whether the cards are qualified. After detection, the cards reach the screening mechanism 4. For unqualified cards, the jet assembly 41 jets air to press down the head of the card, the limiting assembly 42 presses down the tail of the card, and the guide roller 431 assists the card to be rolled into the gap 21; qualified cards cross the gap 2 and enter the second conveyor belt 12. On the second conveyor belt 12, the counting sensor 62 counts the number of cards, the deceleration wheel 63 decelerates the cards and uses the protrusions 632 to physically group them, and the first image acquisition unit 61 observes whether the cards are congested on the second conveyor belt 12. Subsequently, the cards are intercepted and stacked by the support member 722 at the sorting mechanism 7 and pushed to the third conveyor belt 13 by the auxiliary conveying assembly 71. Finally, when the sensor 83 detects that a certain number of card groups have arrived on the third conveyor belt 13, the pusher plate 82 pushes the cards into the packaging assembly 8 to complete the packaging.

[0065] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An automated device for card sorting, characterized in that, The end of the card located downstream in the direction of transmission is the pilot end, and the end of the card located upstream in the direction of transmission is the rear end, including: The conveying mechanism (1) includes a first conveyor belt (11) and a second conveyor belt (12). The first conveyor belt (11) is used to convey cards to be screened, and the second conveyor belt (12) is used to convey cards that have been screened. The top surfaces of the first conveyor belt (11) and the second conveyor belt (12) are on the same horizontal plane. A gap (2) is left between the first conveyor belt (11) and the second conveyor belt (12). The gap (2) is used for unqualified cards to leave the conveying mechanism (1). The detection mechanism (3) is spaced apart from the first conveyor belt (11). The detection mechanism (3) is used to detect the cards to be screened and to classify the cards as qualified or unqualified. The screening mechanism (4) includes an air jet assembly (41) and a limiting assembly (42). The air jet assembly (41) is configured to jet air toward the gap (2) to bend the leading end of the defective card toward the gap (2). The limiting assembly (42) is spaced above the unloading end of the first conveyor belt (11) to prevent the card from moving upward. When the first conveyor belt (11) conveys the leading end of a qualified card to the gap (2), the jet assembly (41) will not jet downwards, allowing the qualified card to cross the gap (2) by its own inertia and move to the second conveyor belt (12); when the first conveyor belt (11) conveys the leading end of an unqualified card to the gap (2), the jet assembly (41) jets downwards, causing the leading end of the unqualified card to bend toward the gap (2), and the limiting assembly (42) prevents the rear end of the card from tilting upwards, allowing the unqualified card to enter the gap (2).

2. The automated device for card sorting according to claim 1, characterized in that, The limiting component (42) includes a limiting belt (421) and multiple rotating wheels (422). The multiple rotating wheels (422) are driven to rotate in the same direction as the conveying direction of the first conveyor belt (11). The limiting belt (421) is sleeved on the outer circumferential surface of the multiple rotating wheels (422) and driven to connect with the multiple rotating wheels (422). The portion of the limiting belt (421) corresponding to the conveying mechanism (1) is horizontally arranged and spaced above the conveying mechanism (1).

3. The automated device for card sorting according to claim 2, characterized in that, The height of the limiting component (42) is adjustable in the vertical direction, and the position of the limiting component (42) is adjustable in the width direction of the first conveyor belt (11) so that the limiting component (42) can be spaced above the center position of the various sizes of cards to be screened.

4. The automated device for card sorting according to claim 1, characterized in that, The jet assembly (41) includes at least two jet elements (411), which are slidably connected to the limiting assembly (42). The positions of the at least two jet elements (411) along the width direction of the first conveyor belt (11) are adjustable. The at least two jet elements (411) are spaced apart on both sides of the limiting assembly (42) along the width direction of the first conveyor belt (11). The nozzles (4111) of the jet elements (411) are arranged facing the gap (2).

5. The automated device for card sorting according to claim 1, characterized in that, The screening mechanism (4) further includes a guide component (43), which is built into the gap (2). The guide component (43) includes at least two guide rollers (431), which are perpendicular to the conveying direction of the first conveyor belt (11). The at least two guide rollers (431) are spaced apart. The top of the at least two guide rollers (431) is on the same horizontal plane as the top surface of the first conveyor belt (11). The at least two guide rollers (431) are driven to rotate and the rotation direction is the same as the conveying direction of the conveying mechanism (1). A gap (21) is left between the guide roller (431) closest to the first conveyor belt (11) and the first conveyor belt (11). The gap (21) is used for unqualified cards to leave the conveying mechanism (1).

6. The automated device for card sorting according to claim 1, characterized in that, The automated device for card sorting also includes a control mechanism (5) and a counting mechanism (6); wherein, the counting mechanism (6) is spaced apart from the second conveyor belt (12), and the counting mechanism (6) includes a first image acquisition unit (61), a counting sensor (62), a reduction wheel (63), and an alarm unit (64). The counting sensor (62) is spaced above the second conveyor belt (12) and its position is adjustable along the width direction of the second conveyor belt (12); the position of the reduction wheel (63) along the width direction of the second conveyor belt (12) is adjustable, and the reduction wheel (63) along the vertical direction... The height is adjustable. The deceleration wheel (63) cooperates with the second conveyor belt (12) to reduce the speed of the cards conveyed from the first conveyor belt (11) to the second conveyor belt (12). The first image acquisition device (61) is located downstream of the deceleration wheel (63) relative to the conveying direction of the second conveyor belt (12) and is used to acquire the conveying status of the screened cards after being decelerated by the deceleration wheel (63). The first image acquisition device (61) and the counting sensor (62) are respectively connected to the control mechanism (5) for communication. The alarm device (64) is electrically connected to the control mechanism (5).

7. The automated device for card sorting according to claim 6, characterized in that, The reduction wheel (63) includes a rotating part (631) and a protruding part (632). The protruding part (632) is a protruding structure that extends radially outward from the outside of the rotating part (631). When the card is conveyed by the second conveyor belt (12) and passes through the bottom of the reduction wheel (63), it will drive the reduction wheel (63) to rotate. By adjusting the conveying speed of the second conveyor belt (12), the number of cards passing through the bottom of the reduction wheel (63) in one rotation can be determined. The protruding part (632) is used to separate the determined number of cards.

8. The automated device for card sorting according to claim 6, characterized in that, The conveying mechanism (1) further includes a third conveyor belt (13), which is disposed at the end of the second conveyor belt (12) away from the first conveyor belt (11); The automated device for card sorting also includes a sorting mechanism (7), which further includes an auxiliary conveying component (71) and a support component (72). The support component (72) is located downstream of the counting mechanism (6) relative to the conveying direction of the second conveyor belt (12). The support component (72) also includes a receiving member (721) and a support member (722). The support member (722) is spaced above the second conveyor belt (12) and driven to abut or separate from the top surface of the second conveyor belt (12) to block or allow cards to continue to be conveyed by the second conveyor belt. (12) Conveying, the receiving member (721) is located downstream of the support member (722) relative to the second conveyor belt (12); the auxiliary conveying component (71) is located downstream of the support member (722) relative to the conveying direction of the second conveyor belt (12), and the auxiliary conveying component (71) is located upstream of the receiving member (721) relative to the conveying direction of the second conveyor belt (12). The auxiliary conveying component (71) cooperates with the second conveyor belt (12) to convey the card from the second conveyor belt (12) to the third conveyor belt (13).

9. The automated device for card sorting according to claim 8, characterized in that, The automated device for card sorting also includes a packing assembly (8), which is located downstream of the sorting mechanism (7) relative to the conveying direction of the third conveyor belt (13). The packing assembly (8) includes a packing component (81), a pusher plate (82), and a sensor (83). The sensor (83) is communicatively connected to the control mechanism (5), and the packing component (81) is electrically connected to the control mechanism (5). When the sensor (83) senses that there is a card on the upper surface of the third conveyor belt (13), the pusher plate (82) is driven to push the card to the position of the packing component (81), and the packing component (81) packs the card. When the sensor (83) senses that there is no card on the upper surface of the third conveyor belt (13), the pusher plate (82) does not work.

10. The automated device for card sorting according to claim 1, characterized in that, The detection mechanism (3) includes two sets of detection components (31). Each set of detection components (31) includes a three-dimensional image acquisition component (311) for detecting unevenness and a two-dimensional image acquisition component (312) for detecting color difference. One set of detection components (31) is spaced above the first conveyor belt (11), and one three-dimensional image acquisition component (311) and one two-dimensional image acquisition component (312) are positioned facing the top surface of the first conveyor belt (11). The surface of the first conveyor belt (11) is provided with several through holes (111). The other set of detection components (31) is spaced below the first conveyor belt (11), and one three-dimensional image acquisition component (311) and one two-dimensional image acquisition component (312) are positioned facing the bottom surface of the first conveyor belt (11).

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