Automatic insertion control system for laminated partition in bag packaging production line

Abstract

The present application relates to the technical field of automation packaging control, and specifically discloses a kind of automatic insertion control system of laminated baffle for strip bag packaging production line. Mainly solve the problem that baffle blind insertion is prone to physical interference and packaging crushing caused by uneven strip bag stacking, the system includes state detection, shaping intervention, insertion execution, force feedback collection and main control module. The main control module extracts flatness based on surface morphology, automatically intercepts instructions when the safety condition is not met and controls the shaping mechanism to flatten; after reaching the standard, dynamically solve the descent end point and drive insertion; real-time monitoring of dynamic load data during insertion, automatically trigger back-off release and flexible correction action of shaking and retry when interference anomaly occurs. The present application realizes closed-loop verification before insertion and flexible gap-seeking anti-interference during insertion, effectively improves the insertion success rate and avoids damage to the strip bag.

Description

Technical Field

[0001] This invention relates to the field of automated packaging control technology, and specifically discloses an automatic insertion control system for stacked partitions in a strip bag packaging production line. Background Technology

[0002] In strip bag packaging production lines, partitions are typically inserted between multiple layers of strip bags to improve stacking stability and ease of subsequent handling. Most existing production equipment uses a preset program to control the insertion mechanism, which performs a fixed-path descent insertion action after reaching a set number of stacked layers. This method usually uses layer counting or cycle signals as triggering criteria, lacking detection of the actual stacking state of the strip bags at the insertion station, making it difficult to identify localized bulges, tilting, misalignment, or overall unevenness on the strip bag surface.

[0003] In existing inserting processes, the insertion actuator typically presses down directly according to a preset stroke, with fixed insertion depth and endpoint positions, failing to adaptively adjust to fluctuations in the current bag stack height. When the bag stack height changes, issues such as insert position deviation, insertion angle imbalance, and interference with bag edges or stack protrusions can easily occur. Furthermore, existing equipment generally lacks real-time sensing capabilities for load changes and abnormal resistance during insertion; when encountering jamming, it often requires stopping the machine, making it difficult to promptly perform corrective operations such as retraction, force release, or repositioning.

[0004] Therefore, existing partition insertion methods in strip bag packaging production lines generally suffer from problems such as a lack of state determination before insertion, dependence on fixed stroke for insertion position, and a lack of real-time feedback and interference correction capabilities during insertion, making them difficult to adapt to production conditions with significant changes in the stacking state of strip bags. In summary, existing technologies have shortcomings such as rigidity in the automated insertion process, insufficient adaptability to stacking states, and a lack of closed-loop control mechanisms. Summary of the Invention

[0005] The purpose of this invention is to provide an automatic insertion control system for stacked partitions in a strip bag packaging production line, comprising a status detection module, a shaping intervention module, an insertion execution module, a force feedback acquisition module, and a main control module. The status detection module acquires the surface morphology and height distribution data of the currently stacked strip bags at the insertion station; the shaping intervention module performs posture shaping actions such as flattening or vibration on the stacked strip bags; the insertion execution module grips the partition and drives it to perform a descending insertion action between the stacked strip bags; the force feedback acquisition module collects the dynamic load data of the insertion execution module in real time during the descending insertion action; the main control module is communicatively connected to the status detection module, the shaping intervention module, the insertion execution module, and the force feedback acquisition module. The core innovation of this invention lies in constructing an automatic insertion control system for stacked partitions in strip bags. The closed-loop adaptive control mechanism of the process no longer adopts the rigid insertion method based on fixed layer triggering and fixed stroke pressing in the existing technology. Instead, it integrates the state perception before insertion, the load feedback during insertion, and the correction action after insertion: the state detection module obtains the surface morphology and height distribution data of the stacked bags, and uses the flatness characteristics as the pre-insertion criterion. If the safety conditions are not met, the shaping intervention is triggered before insertion is allowed; the target descent endpoint of the partition is dynamically calculated based on the current actual height distribution, thereby replacing the fixed insertion depth; dynamic load data is collected in real time during the insertion process, and when an abnormal change is detected, a flexible gap-finding and correction strategy is automatically executed to release the force and try to insert again.

[0006] The objective of this invention can be achieved through the following technical solutions: The automatic insertion control system for stacked partitions in a strip bag packaging production line includes the following modules: The status detection module is used to acquire the surface morphology and height distribution data of the currently stacked strip bags at the insertion station; The shaping intervention module is used to perform posture shaping actions such as flattening or vibration on the stacked strip bags; An insertion execution module is used to grip the partition and drive the partition to perform a descent insertion action between the layers of the stacked strip bags; The force feedback acquisition module is used to acquire the dynamic load data of the insertion execution module in real time during the descent insertion action; The main control module is communicatively connected to the state detection module, the shaping intervention module, the insertion execution module, and the force feedback acquisition module. The main control module is configured to execute a closed-loop insertion control mechanism containing the following logic: Based on the surface morphology data acquired by the state detection module, flatness features are extracted; when the flatness features do not meet a preset safety condition, the insertion command is intercepted, and the shaping intervention module is controlled to perform attitude shaping actions until the re-acquired flatness features meet the safety condition; after determining that the safety condition has been met, the vertical target descent endpoint of this partition insertion is dynamically calculated based on the current actual height distribution data acquired by the state detection module; the insertion execution module is controlled to move towards the target descent endpoint, and the dynamic load data fed back by the force feedback acquisition module is monitored synchronously; when it is detected that the target descent endpoint has not yet been reached and the dynamic load data undergoes an abnormal change, insertion interference is determined, and the insertion execution module is controlled to perform a correction action of retraction and force release before attempting insertion again.

[0007] Preferably, the state detection module includes a 3D vision camera; Based on the point cloud data collected by the state detection module, the height range of the currently stacked strip bags is calculated, and the height range is used as the flatness feature; the preset safety condition is that the height range is less than the preset height tolerance threshold.

[0008] Preferably, the shaping intervention module includes a top flattening mechanism and a side patting mechanism; When the main control module determines that the flatness feature has not reached the preset safety conditions, it locates the abnormal height area according to the surface morphology data: if it is a local bulge, it controls the top flattening mechanism to press down and shape the bulging area; if it is a stacking misalignment, it controls the lateral tapping mechanism to perform horizontal centering tapping and shaping.

[0009] Preferably, the specific logic for the main control module to dynamically calculate the target descent endpoint is as follows: Extract the highest point height value from the actual height distribution data, add the preset thickness value of the partition and the preset safety gap compensation value to the highest point height value, and calculate the absolute coordinates of the vertical target descent endpoint.

[0010] Preferably, the insertion execution module includes a servo drive motor, a linear module driven by the servo drive motor, and a vacuum suction cup clamp mounted at the end of the linear module. The force feedback acquisition module is electrically connected to the servo drive motor and is used to acquire the output torque of the servo drive motor in real time and convert it into the dynamic load data.

[0011] Preferably, the logic for the main control module to determine if the dynamic load data has experienced an abnormal change is as follows: Calculate the rate of change of the output torque within a continuous sampling period; when the current position of the insertion execution module has not yet reached the target descent endpoint, and the absolute value of the output torque exceeds the preset anti-crushing threshold, or the rate of change of the output torque exceeds the preset rate of change threshold, it is determined that an insertion interference has occurred.

[0012] Preferably, the correction action of controlling the insertion execution module to attempt insertion again after performing the retraction release force specifically includes the following steps: The insertion execution module is controlled to immediately stop pressing down and retract vertically by a first preset distance to release the compressive stress; In the retraction position, the insertion execution module is controlled to perform micro-amplitude high-frequency jitter in the horizontal direction to find interlayer gaps; At a compensating speed lower than the initial downward speed, the partition is driven again to move towards the target descent endpoint.

[0013] Preferably, the main control module also has a preset maximum number of correction retry attempts; When performing the correction action, the main control module counts simultaneously. If the number of retries reaches the maximum number of correction retries and insertion interference is still detected, the main control module determines that the insertion at the station has failed, triggers an audible and visual alarm command, and controls the production line to pause.

[0014] Preferably, the main control module is also configured with an adaptive learning algorithm for dynamically updating the abnormal change judgment threshold of the dynamic load data; The adaptive learning algorithm records the maximum dynamic load peak value during the previous N successful interference-free insertion processes and calculates a moving average value in combination with a preset fluctuation coefficient. This moving average value is then used as the benchmark threshold for judging abnormal mutations in the current insertion.

[0015] Preferably, the main control module is configured to issue a preparatory command in parallel during the same time period when controlling the shaping intervention module to perform the posture shaping action; the preparatory command is used to control the insertion execution module to move to the partition hopper in advance to complete the partition clamping, and wait above the insertion station until the flatness feature re-acquired reaches the safety condition, and then immediately perform the insertion action downward.

[0016] The beneficial effects of this invention are: This invention introduces the detection of the surface morphology and height distribution of the stacked bags before the partition is inserted, and performs shaping intervention first when the flatness does not meet the conditions. This makes the insertion action no longer based on a simple fixed rhythm or fixed number of layers, thereby effectively reducing insertion interference, jamming and insertion failure caused by uneven stacking, local protrusions or posture misalignment, and improving the stability and continuity of the partition insertion process.

[0017] This invention dynamically calculates the target descent endpoint of the partition insertion based on the actual height distribution of the current bag stack, so that each insertion action can match the real-time stacking state. This avoids problems such as insertion depth deviation, inaccurate partition position, and squeezing and collision with the edge of the bag that are easy to occur in the traditional fixed stroke method, thereby improving the adaptability of the partition insertion position and the accuracy of action control.

[0018] This invention acquires dynamic load data in real time during insertion and automatically performs correction actions such as retraction and re-insertion when abnormal resistance is detected. This enables the system to have online sensing and flexible processing capabilities during the insertion process, reducing mechanical impact, manual intervention, and downtime caused by sudden interference. This helps maintain the stability and automation of the packaging production line. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the automatic insertion control system for the stacked partitions in the strip bag packaging production line of the present invention. Detailed Implementation

[0020] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0021] Example: Figure 1 As shown, the automatic insertion control system for stacked partitions in the strip bag packaging production line of the present invention mainly includes: a status detection module, a shaping intervention module, an insertion execution module, a force feedback acquisition module, and a main control module.

[0022] The status detection module is positioned above or slightly above the insertion station to acquire data on the surface morphology and height distribution of the currently stacked bags. This status detection module preferably uses a 3D vision camera, but can also employ a laser contour sensor or structured light sensor with contour scanning capabilities. In a preferred embodiment, the 3D vision camera is fixedly mounted directly above the insertion station, acquiring three-dimensional point cloud data of the top of the stacked bags from a top-down perspective. To improve recognition accuracy, an auxiliary light source can be provided in the station area to reduce the impact of packaging film reflection on the measurement results.

[0023] The shaping intervention module is used to perform flattening, tapping, vibration, or local shaping operations on the stacked bags when the detection results show that the bag stack does not meet the insertion safety conditions. Preferably, the shaping intervention module includes a top flattening mechanism and a side tapping mechanism. The top flattening mechanism can be a cylinder-driven pressure plate, a servo-electric cylinder-driven pressure head, or a flexible pressure roller; the side tapping mechanism can be a symmetrically arranged tapping plate, push plate, or flexible straightening mechanism, used to center and shape the stacked contour.

[0024] The insertion execution module is used to grip the partition from the partition feeding position and drive the partition to the interlayer of the stacked strip bags to perform a descent insertion action. In a preferred embodiment, the insertion execution module includes a servo drive motor, a Z-axis linear module driven by the servo drive motor, and a vacuum suction cup clamp mounted at the end of the linear module. To facilitate actions such as retraction, micro-jittering, and re-pressing, the linear module preferably has high position control accuracy and speed response capability. If necessary, the insertion execution module may also include an X-axis or Y-axis fine-tuning mechanism to cooperate with the correction action to perform interlayer gap finding.

[0025] The force feedback acquisition module is used to acquire dynamic load data in real time during the insertion process of the insertion execution module. Preferably, the force feedback acquisition module is electrically connected to the servo drive motor, and obtains the load change during the insertion process by reading the output torque value, current value, or equivalent load rate fed back by the driver. Furthermore, a miniature force sensor can also be set at the clamp end to fuse the force at the clamp end with the servo torque data to form a more reliable dynamic load signal.

[0026] The main control module is an industrial controller, PLC, motion controller, or industrial computer, which communicates with the status detection module, shaping intervention module, insertion execution module, and force feedback acquisition module, respectively. The main control module executes the entire closed-loop insertion control logic, including flatness feature extraction, safety condition determination, shaping action triggering, dynamic calculation of insertion endpoint, pressure control, dynamic load anomaly determination, back-off force release, jitter retry, failure alarm, and learning update, etc.

[0027] The working principle of this invention is as follows: After reaching the required number of partition insertion layers or after the upper-level scheduling system issues an insertion task, the main control module does not immediately control the insertion execution module to perform blind insertion. Instead, it first triggers the status detection module to scan and sample the surface morphology and height distribution of the currently stacked strip bags at the insertion station. The main control module extracts flatness features from the collected three-dimensional point cloud data to determine whether the top of the current stack meets the safe insertion conditions.

[0028] If the flatness characteristics do not meet the preset safety conditions, the main control module intercepts the insertion command, prohibits the insertion execution module from inserting downwards, and controls the shaping intervention module to start the shaping action. If the detection result shows local bulges, the top flattening mechanism will press down and flatten the bulging area; if the detection result shows local skewness, offset, or overall outline eccentricity of the bag, the lateral tapping mechanism will perform lateral tapping or centering. After the shaping is completed, the status detection module will collect a new round of surface morphology data, and the main control module will recalculate the flatness characteristics and re-judge them until the safety conditions are met.

[0029] Once the flatness characteristics meet the safety requirements, the main control module further calculates the target descent endpoint of the current partition insertion based on the current actual height distribution data. Unlike traditional fixed stroke schemes, this invention does not use a single fixed pressing depth, but dynamically calculates the termination position of the insertion based on the current actual highest point of the stack, the partition thickness, and the reserved safety gap, thereby matching the insertion endpoint with the current actual working conditions.

[0030] Subsequently, the main control module controls the insertion execution module to grasp the partition and move it towards the target descent endpoint. During the descent, the force feedback acquisition module collects the servo output torque in real time and feeds it back to the main control module. If the main control module detects an abnormal change in dynamic load or an absolute value exceeding the safety threshold before reaching the target descent endpoint, it determines that interference such as strip bag compression, edge collision, or misalignment between layers has occurred during the insertion process. At this time, the main control module immediately controls the insertion execution module to stop pressing down, reverse and retract a preset distance to release the compression stress, and then perform a slight horizontal shaking or swinging motion to find the gap between layers, and then perform a second insertion at a compensation speed lower than the first pressing down. If it is still unsuccessful after multiple retries, the system issues an alarm and suspends the production line, awaiting manual intervention.

[0031] In this embodiment, the state detection module uses a 3D vision camera. Before each insertion, the 3D vision camera scans the top area of ​​the stacked strip bags to obtain a three-dimensional point set on the workstation surface. To improve processing stability, the main control module first performs boundary clipping, outlier removal, and smoothing filtering on the original point cloud, retaining only the point cloud data within the effective workstation range. Then, the point cloud height values ​​are mapped onto a two-dimensional grid to form a corresponding height matrix, which is used to calculate the flatness features.

[0032] In this embodiment, the height range within the effective area at the top of the stack is used as the main flatness feature, and its calculation formula is as follows: ,in, This indicates the height difference flatness index of the top of the current stack of bags; This represents the maximum height value among all sampling points within the effective detection area; This represents the minimum height value among all sampling points within the effective detection area. The main control module will then calculate the required height. Compare with the preset height tolerance threshold. If If the flatness of the top of the current stack of bags meets the safety requirements, then it is considered that the flatness of the top of the stack meets the safety requirements; if If the condition is found to be out of tolerance due to protrusions, collapses, or misalignments, then reconstructive intervention is required. Specifically: This indicates the height tolerance threshold for allowed insertion.

[0033] In another preferred implementation, local window range or grid variance can be introduced as an auxiliary index. In this embodiment, the height range value is used as the main flatness feature criterion.

[0034] To further pinpoint abnormal areas, the main control module can divide the effective area into multiple sub-regions and calculate the local maximum height and relative average height deviation for each sub-region. When the relative deviation of a sub-region exceeds the region determination threshold, the main control module marks that sub-region as a height abnormality region and generates the target coordinates for the shaping action.

[0035] When the main control module determines that the flatness does not meet the safety requirements, the system performs a shaping intervention. The shaping intervention is not a fixed action, but rather a differentiated treatment based on the classification of abnormal shapes.

[0036] Localized bulge shaping: If the height of a certain local area is significantly higher than the surrounding area, and the abnormal area is small, the main control module determines it as a localized bulge. At this time, the top flattening mechanism moves above the target area and applies downward pressure with a preset pressure or preset displacement to locally flatten the bulge area. After the flattening action is completed, it is lifted, and the status detection module rescans the top status.

[0037] Overall skew or eccentricity correction: If the detection results show that the stacked outline center is offset, the two side boundaries are asymmetrical, or abnormal height areas are continuously distributed along the sides, the main control module determines that the stacking is misaligned. At this time, the lateral tapping mechanism performs centering tapping on both sides of the stacked strip bags, so that the locally misaligned strip bags are brought back to the center to improve the interlayer alignment.

[0038] Shaping Cycle Number Control: To prevent the shaping action from repeating indefinitely, the main control module can set a maximum number of shaping cycles. If the safety conditions are still not met after reaching the maximum number of cycles, the system outputs an abnormal workstation signal, prompting manual intervention. This logic is an optional protection provision; even if not separately included in the claims, it is still an engineering measure that can be adopted during the implementation of this invention.

[0039] After the safety conditions are met at the top of the stack, the main control module needs to determine the target descent endpoint for this partition insertion. Traditional equipment typically uses a fixed compression depth, but when the stack height of the bags varies with factors such as batch size, bag quantity, sealing bulges, and stacking deviations, a fixed stroke can easily lead to insufficient or excessive compression. This invention calculates the endpoint position based on the real-time height distribution.

[0040] In this embodiment, the absolute coordinates of the target's descent endpoint in the vertical direction are calculated as follows: ,in, This indicates the absolute coordinates of the vertical target descent endpoint during this partition insertion action; This indicates the highest point height value in the currently stacked bag top effective area; This indicates the preset thickness value of the partition to be inserted; This indicates the safety gap compensation value reserved when the partition is inserted to avoid directly compressing the bag.

[0041] In practical implementation, if the system coordinate system takes the equipment reference plane as its zero point, then The coordinates are the target position coordinates measured from the reference plane; if the system coordinate system uses the initial standby position of the plug as a reference, the absolute coordinates can be further converted into relative motion. The main control module determines the relative motion based on the real-time position of the currently inserted execution module. The difference is used to generate a descent command, enabling real-time closed-loop position control.

[0042] If necessary, different settings can be made according to different specifications of partitions, different strip bag thicknesses, and different interlayer compression characteristics. and The parameter table is automatically retrieved by the main control module according to the current production formula.

[0043] The insertion execution module preferably uses a servo drive motor in conjunction with a linear module to achieve high-precision position and speed control. A vacuum suction cup clamp is installed at the end of the linear module to pick up a single partition from the partition hopper and, after moving above the insertion station, aligns it with the interlayer of the strip bag to perform a pressing action.

[0044] The force feedback acquisition module can directly read the output torque value fed back by the servo driver. Since the servo output torque will suddenly increase when encountering obstruction or jamming during insertion, this can be used to determine whether interference has occurred. For more complex designs, the servo torque can be fused with the force sensor data at the fixture end to obtain a comprehensive load index; however, this embodiment uses the servo output torque as the primary load data source.

[0045] To suppress sampling noise, the main control module performs a moving average or low-pass filtering on the original torque sequence before calculating the rate of change and determining the threshold. The load data sampling period is preferably synchronized with the servo control period to improve the timeliness of anomaly detection.

[0046] During the insertion execution module's descent towards the target endpoint, the main control module continuously compares "whether the current position has reached the target endpoint" with "whether the dynamic load is abnormal." If the endpoint has not been reached but the load has clearly exceeded the limit, insertion interference is determined to have occurred.

[0047] To identify sudden torque changes, this embodiment uses the torque change rate over a continuous sampling period as a criterion, and its calculation formula is as follows: ,in, This indicates the rate of change of output torque within the current sampling period; This represents the servo output torque value at the k-th sampling time. This represents the servo output torque value at the (k-1)th sampling time. This represents the time interval between two adjacent torque sampling times.

[0048] when If the resistance is too high, it indicates that the resistance increases rapidly in a short period of time during the insertion process. This is most likely due to the front end of the partition hitting the edge of the strip bag, misalignment of the interlayer entrance, local undulations on the surface of the strip bag forming an obstruction, or interference between the fixture and the workpiece.

[0049] In this embodiment, the determination of "position not reaching the endpoint" and "absolute torque value exceeding the limit" is combined, and the determination condition can be expressed as follows: ,in, Indicates the result of the insertion interference determination; when When an insertion interference is detected; when This indicates that no insertion interference has occurred; This indicates the actual descent position of the currently inserted execution module; This indicates the target descent endpoint position obtained from this dynamic calculation; This represents the absolute value of the dynamic load at the current sampling moment, preferably the absolute value of the servo output torque; This indicates the preset anti-crush load threshold.

[0050] In another preferred implementation, the main control module can also use a composite criterion: when the torque change rate Exceeding the rate of change threshold, or the absolute value of the load Exceeding the crush prevention threshold If the current position has not yet reached the target descent endpoint, an insertion interference can be determined. This composite criterion can improve the ability to identify different types of interference.

[0051] Once the main control module determines that an insertion interference has occurred, it immediately stops the current rigid pressing action and switches to a flexible correction process. This correction process includes several stages: stopping, retraction, force release, gap finding, and low-speed re-insertion.

[0052] Immediate Stop Phase: The main control module sends an emergency stop and deceleration command to the servo drive, causing the insertion execution module to stop pressing down to prevent further compression of the strip bag or damage to the partition.

[0053] Retraction and stress release phase: After stopping, the insertion execution module retracts vertically in the opposite direction by a first preset distance, causing the leading edge of the partition to disengage from the blocking position and releasing the local compressive stress between the strip bag and the partition. The retraction distance can be preset according to the partition hardness, strip bag flexibility, and mechanism response.

[0054] Micro-amplitude high-frequency shaking gap-finding stage: At the retraction position, the main control module controls the insertion execution module to perform micro-amplitude high-frequency shaking in the horizontal direction. The shaking direction can be unidirectional reciprocating in the X direction, or a combination of micro-oscillation in the XY plane. This action is used to make the leading edge of the partition perform micro-positioning near the interlayer entrance of the strip bag, thereby finding a smoother interlayer gap.

[0055] Low-speed re-insertion phase: After completing the jittering action, the main control module re-controls the insertion execution module to move towards the target descent endpoint at a compensated speed lower than the initial downward speed. Reducing the speed minimizes impact and facilitates smooth sliding in upon re-contact with the inter-level entrance.

[0056] The peak torque during normal insertion may vary depending on the batch of bags, the packaging film material, and the servo friction state. To enhance system adaptability, this embodiment introduces an adaptive learning algorithm to update the anomaly detection threshold. The calculation formula is as follows: ,in, This indicates the dynamic load anomaly judgment benchmark threshold used for the current insertion; This indicates the number of successful insertions in the history that are included in the statistics; This represents the maximum dynamic load peak value during the j-th successful interference-free insertion process; This represents the preset fluctuation coefficient. After each successful insertion, the main control module writes the maximum dynamic load peak value of that insertion into the historical sample queue. When the number of samples reaches... Automatically calculate new thresholds. Then you can Used for crush prevention threshold The update source can be used as a supplementary reference value beyond the rate of change threshold. Through this adaptive learning process, the system can gradually adapt to the current friction state of the equipment and the operating conditions of the product, reducing the misjudgment rate.

[0057] To ensure production cycle time and equipment safety, this embodiment presets a maximum number of correction retry attempts in the main control module. Each time the system executes the "retracting force release—micro-jitter gap finding—low-speed re-insertion" process, the retry count is incremented by one. If insertion is successful before reaching the maximum number of correction retry attempts, the main control module resets the retry count to zero and enters the next cycle. If insertion interference is still determined after the preset upper limit of retry attempts, the main control module considers the insertion at that station to have failed, issues an audible and visual alarm, and controls the current production line to pause. At this time, operators can check for problems such as partition deformation, severe misalignment of the strip bags, abnormal adsorption, or foreign object blockage.

[0058] In engineering implementation, the main control module can also record point cloud screenshots, torque curves, current positions, and number of retries at the moment of failure, so as to conduct post-sales analysis and process optimization.

[0059] In this embodiment, the main control module also supports parallel preparatory action control. Specifically, when the system determines that the flatness does not meet the safety conditions and initiates shaping intervention, the main control module can issue preparatory commands in parallel, causing the insertion execution module to first go to the partition hopper to pick up the next partition and move to the top of the insertion station to wait. In this way, when the shaping is completed and the re-inspection is qualified, the insertion execution module does not need to pick up the board from the remote hopper again and can directly perform the pressing action, thereby reducing the idle stroke waiting time.

[0060] The prerequisite for implementing this parallel mechanism is that there is no mechanical interference between the shaping action path and the standby position of the insertion execution module. To this end, a safe standby space can be pre-designed in the mechanical layout of the equipment, and action interlock conditions can be set in the main control module: the formal insertion is only allowed when the insertion execution module reaches the waiting area and the shaping mechanism completes the avoidance action.

[0061] The following is a complete preferred embodiment: At a stacking station on the bag packaging production line, after a set number of bags are stacked, the host computer sends an insertion task to the main control module. The main control module first controls a 3D vision camera to scan the top of the bags, obtaining a point cloud of the station's top. After boundary trimming, the main control module calculates the height range. Exceeding the tolerance threshold The system determined that the current conditions for safe insertion were not met. Next, the main control module further analyzed the point cloud and found a localized protrusion in the right front region. Therefore, it controlled the top flattening mechanism to move above this area and perform localized downward pressing and shaping. After shaping, a second scan revealed that the height difference was still slightly above the threshold, and the contour center was shifted to the left. The main control module then controlled the lateral tapping mechanism to gently tap from left to right, causing the bag stack to return to the center. After a second inspection, the flatness met the safety requirements.

[0062] At this time, the main control module determines the height of the highest point. Current partition thickness and safety clearance compensation value Calculate the target descent endpoint Previously, during the shaping action, the insertion module had already moved to the hopper to pick up the partition according to the parallel preparatory instructions and was waiting above the workstation. Therefore, the main control module directly controlled the linear module to start pressing down. During the pressing process, the servo driver continuously transmitted torque values ​​back to the main control module, and the main control module calculated the rate of change in real time. And monitor the absolute value of torque. The current decline has not yet reached... At a certain position, the torque suddenly increases and exceeds the threshold. The main control module immediately detects interference, stops pressing down, and retracts a first preset distance, then performs lateral micro-amplitude high-frequency jitter. After jittering, it descends again at a lower compensation speed. This time, the torque curve is smooth, and it finally reaches the target descent endpoint and completes the partition insertion. The system records the maximum torque peak value and writes it into the historical successful sample sequence for updating the anomaly detection threshold for subsequent batches.

[0063] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0064] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An automatic insertion control system for stacked partitions in a strip bag packaging production line, characterized in that, It includes a status detection module, a shaping intervention module, an insertion execution module, a force feedback acquisition module, and a main control module for communication connections; The status detection module is used to acquire height distribution data of the surface of the stacked strip bags; The main control module is used to extract the maximum and minimum height values ​​within the target area based on the height distribution data, and calculate the height range as a flatness feature. When the height range value is greater than or equal to the preset height tolerance threshold, the insertion command is intercepted, and the shaping intervention module is controlled to perform shaping actions until the newly acquired height range value is less than the threshold. The force feedback acquisition module is used to acquire dynamic load data in real time during the descent insertion. The main control module is also used to calculate the absolute coordinates as the target descent endpoint by adding the partition thickness value and the safety gap compensation value to the maximum height value when the height range value is less than the threshold value. It controls the insertion execution module to move towards the endpoint; it is also used to determine that insertion interference has occurred when it is determined that the current position of the insertion execution module has not yet reached the target descent endpoint and the dynamic load data meets the abnormal conditions, and to control the insertion execution module to perform a correction action; wherein, the abnormal conditions include: the absolute value of the output torque exceeds the preset anti-crushing threshold, or the rate of change of the output torque exceeds the preset rate of change threshold.

2. The automatic insertion control system for stacked partitions in a strip bag packaging production line according to claim 1, characterized in that, The state detection module includes a 3D vision camera; Based on the point cloud data collected by the state detection module, the height range of the currently stacked strip bags is calculated, and the height range is used as the flatness feature. The preset safety condition is that the height range value is less than the preset height tolerance threshold.

3. The automatic insertion control system for stacked partitions in a strip bag packaging production line according to claim 2, characterized in that, The shaping intervention module includes a top flattening mechanism and a side patting mechanism; When the main control module determines that the flatness feature has not reached the preset safety conditions, it locates the abnormal height area based on the surface morphology data: if it is a local bulge, it controls the top flattening mechanism to press down and shape the bulging area; if it is a stacking misalignment, it controls the lateral tapping mechanism to perform horizontal centering tapping and shaping.

4. The automatic insertion control system for stacked partitions in a strip bag packaging production line according to claim 1, characterized in that, The specific logic for the main control module to dynamically calculate the target descent endpoint is as follows: Extract the highest point height value from the actual height distribution data, add the preset thickness value of the partition and the preset safety gap compensation value to the highest point height value, and calculate the absolute coordinates of the target's descent endpoint in the vertical direction.

5. The automatic insertion control system for stacked partitions in a strip bag packaging production line according to claim 1, characterized in that, The insertion execution module includes a servo drive motor, a linear module driven by the servo drive motor, and a vacuum suction cup clamp installed at the end of the linear module. The force feedback acquisition module is electrically connected to the servo drive motor and is used to acquire the output torque of the servo drive motor in real time and convert it into the dynamic load data.

6. The automatic insertion control system for stacked partitions in a strip bag packaging production line according to claim 5, characterized in that, The logic by which the main control module determines when the dynamic load data experiences an abnormal change is as follows: Calculate the rate of change of the output torque within a continuous sampling period; when the current position of the insertion execution module has not yet reached the target descent endpoint, and the absolute value of the output torque exceeds the preset anti-crushing threshold, or the rate of change of the output torque exceeds the preset rate of change threshold, it is determined that an insertion interference has occurred.

7. The automatic insertion control system for stacked partitions in a strip bag packaging production line according to claim 1, characterized in that, The correction action of controlling the insertion execution module to attempt insertion again after performing the retraction and release force includes the following steps: The insertion execution module is controlled to immediately stop pressing down and retract vertically by a first preset distance to release the compressive stress; In the retracted position, the insertion execution module is controlled to perform a slight reciprocating motion in the horizontal direction, and then the partition is driven to move towards the target descent endpoint again at a compensation speed lower than the initial downward speed.

8. The automatic insertion control system for stacked partitions in a strip bag packaging production line according to claim 7, characterized in that, The main control module also has a preset maximum number of correction retry attempts; When performing the correction action, the main control module counts simultaneously. If the number of retries reaches the maximum number of correction retries and insertion interference is still detected, the main control module determines that the workstation insertion has failed, triggers an audible and visual alarm command, and controls the production line to pause.

9. The automatic insertion control system for stacked partitions in a strip bag packaging production line according to claim 6, characterized in that, The main control module is also configured with an adaptive learning algorithm for dynamically updating the abnormal change judgment threshold of the dynamic load data; The adaptive learning algorithm records the maximum dynamic load peak value during the previous N successful interference-free insertion processes and calculates a moving average value in combination with a preset fluctuation coefficient. This moving average value is then used as the benchmark threshold for judging abnormal mutations in the current insertion.

10. The automatic insertion control system for stacked partitions in a strip bag packaging production line according to claim 1, characterized in that, The main control module is configured to issue a preparatory command in parallel during the same time period when controlling the shaping intervention module to perform the posture shaping action; the preparatory command is used to control the insertion execution module to move to the partition hopper in advance to complete the partition clamping, and wait above the insertion station until the flatness feature re-acquired reaches the safety condition and then immediately perform the insertion action downward.

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