A tray separation control method and system for a tray unstacker

Abstract

The application discloses a tray separation control method and system of a tray unstacking machine, and relates to the technical field of automatic logistics equipment control, which comprises the following steps: applying a tentative excitation force to a tray stack, and obtaining force response data; determining a load transmission path in the tray stack according to the force response data, and determining the influence degree of each load transmission path on overall load transmission; predicting the load distribution change after the corresponding load transmission path is removed based on the influence degree; generating a separation action sequence according to the influence degree and the corresponding load distribution change, and controlling the tray unstacking machine to perform a separation operation according to the separation action sequence; and updating the load transmission path according to the force response data after the separation operation, and regenerating the separation action sequence until the tray separation is completed. Through the analysis and dynamic updating of the load transmission state of the tray stack, the application realizes the adaptive generation of the separation action sequence, and improves the stability and separation efficiency of the tray separation process.

Description

Technical Field

[0001] This invention relates to the field of logistics automation equipment control technology, and more specifically, to a pallet separation control method and system for a pallet destacking machine. Background Technology

[0002] A pallet destacking machine is a logistics device used to automatically split pallet stacks and retrieve pallets. It is widely used in warehousing and logistics, automated production lines, and intelligent distribution. Existing pallet destacking machines typically use a lifting mechanism, a clamping mechanism, and a drive mechanism working together to separate pallet stacks layer by layer and output individual pallets, thus replacing manual pallet unpacking and improving pallet supply efficiency and automation levels.

[0003] Most existing pallet destacking machines control pallet separation according to preset actions or a fixed separation sequence. This means they separate pallets based on pre-set lifting heights, clamping positions, and execution sequences, failing to dynamically adjust the separation sequence according to the actual stress state at each contact point of the pallet stack. When the stress state at each contact point varies due to manufacturing errors, long-term stacking, localized deformation, moisture, or different loads, a fixed separation sequence can easily cause excessive loads on localized areas, leading to pallet jamming, displacement, localized compression, or even separation failure, affecting destabilization efficiency and equipment operational stability.

[0004] Therefore, how to analyze the load transfer between pallets based on the actual stress state of the pallet stack, predict the impact of different separation methods on the load distribution of the pallet stack, and dynamically generate a separation action sequence accordingly to complete pallet separation while ensuring the overall stability of the pallet stack has become a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0005] To overcome the aforementioned deficiencies of the prior art, embodiments of the present invention provide a pallet separation control method and system for a pallet stacking machine. By constructing a pallet stack load transfer path, predicting the load distribution changes after the load transfer path is removed, and generating a separation action sequence based on the prediction results, dynamic planning and closed-loop updating of the pallet separation process are realized, thereby improving the stability and operational efficiency of pallet separation.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A pallet separation control method for a pallet destacking machine includes the following steps: applying a trial excitation force to the pallet stack and acquiring force response data, wherein the amplitude of the trial excitation force is less than the minimum separation force required for separating a single layer of pallets; determining the load transfer path in the pallet stack based on the force response data and determining the degree of influence of each load transfer path on the overall load transfer, wherein the load transfer path is formed by connecting pallet combinations with load transfer relationships according to the load transfer direction; predicting the load distribution change after removing the corresponding load transfer path based on the degree of influence; generating a separation action sequence based on the degree of influence and the corresponding load distribution change, and controlling the pallet destacking machine to perform separation operations according to the separation action sequence; updating the load transfer path based on the force response data after the separation operation and regenerating the separation action sequence until pallet separation is completed.

[0007] In a preferred embodiment, applying a trial excitation force to the pallet stack and obtaining force response data includes: applying a trial excitation force in a first direction to the pallet stack and obtaining first force response data; determining the pallet area with a large force change based on the first force response data; partially releasing the load on the pallet area and applying a trial excitation force in a second direction to obtain second force response data; and comparing the first and second force response data to determine the degree of force influence between each pallet.

[0008] In a preferred embodiment, determining the load transfer path in the pallet stack based on the force response data includes: determining the pallet combinations with load transfer based on the degree of force influence; determining the load transfer direction based on the force response timing relationship corresponding to each pallet combination; connecting the corresponding pallet combinations according to the load transfer direction to form a continuous load transfer path; determining the load transfer capacity based on the degree of force influence corresponding to each continuous load transfer path, and outputting each continuous load transfer path as a load transfer path.

[0009] In a preferred embodiment, determining the degree of influence of each load transfer path on the overall load transfer includes: sequentially taking each load transfer path as a target load transfer path, simulating the load redistribution process after removing the target load transfer path, and determining the load change amount corresponding to the remaining load transfer paths; determining the load concentration area based on the load change amount corresponding to each load transfer path; and determining the degree of influence of the target load transfer path on the overall load transfer based on the load increment and distribution range of the load concentration area.

[0010] In a preferred embodiment, the step of predicting the load distribution change after removing the corresponding load transfer path based on the degree of influence includes: obtaining the load transfer capacity corresponding to the target load transfer path; determining the load transfer priority order based on the load transfer capacity and current load percentage of each load transfer path connected to the target load transfer path; allocating the load borne by the target load transfer path to each load transfer path according to the load transfer priority order; and determining the load percentage of each load transfer path after redistribution as the load distribution change after removing the target load transfer path.

[0011] In a preferred embodiment, generating the separation action sequence based on the degree of influence and the corresponding load distribution change includes: determining the sequential execution relationship between any two load transmission paths based on the degree of influence corresponding to each load transmission path and the load distribution change after removal; generating multiple candidate separation sequences based on the sequential execution relationship between each load transmission path; predicting the load distribution change corresponding to each candidate separation sequence and determining the corresponding maximum load concentration degree; and determining the candidate separation sequence with the minimum maximum load concentration degree as the separation action sequence.

[0012] In a preferred embodiment, determining the sequential execution relationship between any two load transfer paths includes: predicting the load increment of the second load transfer path after the first load transfer path is released; determining that the second load transfer path is executed before the first load transfer path when the load increment exceeds a preset threshold; predicting the load concentration degree after any two load transfer paths are released consecutively; determining that the two load transfer paths are not executed consecutively when the load concentration degree exceeds a preset threshold; predicting the overall support state of the pallet stack after the target load transfer path is released; and determining that the target load transfer path is executed last when the prediction result indicates that the pallet stack loses stable support after the target load transfer path is released.

[0013] In a preferred embodiment, the control of the destacking and stacking machine to perform separation operations according to a separation action sequence includes: determining the current target separation area according to the separation action sequence, wherein the target separation area is determined according to the spatial position corresponding to the load transfer path; controlling the destacking and stacking machine to perform partial lifting, partial clamping and releasing, or partial pushing operations in the current target separation area; and performing the separation operation of the next target separation area after completing the separation of the current target separation area.

[0014] A pallet separation control system for a pallet destacking machine includes: an excitation acquisition module for applying a trial excitation force to a pallet stack and acquiring force response data, wherein the amplitude of the trial excitation force is less than the minimum separation force required for separating a single layer of pallets; a path analysis module for determining the load transfer path in the pallet stack based on the force response data and determining the degree of influence of each load transfer path on the overall load transfer, wherein the load transfer path is formed by connecting pallet combinations with load transfer relationships according to the load transfer direction; a load prediction module for predicting the load distribution change after removing the corresponding load transfer path based on the degree of influence; an action planning module for generating a separation action sequence based on the degree of influence and the corresponding load distribution change, and controlling the pallet destacking machine to perform separation operations according to the separation action sequence; and a feedback update module for updating the load transfer path based on the force response data after the separation operation and regenerating the separation action sequence until pallet separation is completed.

[0015] A pallet destacking machine includes: a frame, a lifting mechanism, a clamping mechanism, a driving mechanism, a force detection device, a processor, and a memory; the force detection device is used to acquire force response data of the pallet stack; the processor is connected to the force detection device, the lifting mechanism, the clamping mechanism, and the driving mechanism respectively; the memory stores a computer program, and when the computer program is executed by the processor, the processor performs the pallet separation control method of any one of the pallet destacking machines described above.

[0016] The technical effects and advantages of the tray separation control method and system for a tray destacking machine of the present invention are as follows: 1. This invention obtains the stress response data of the pallet stack, determines the load transfer path in the pallet stack, and analyzes the influence of each load transfer path on the overall load transfer. It can reflect the load transfer state inside the pallet stack, provide a separation basis that matches the actual stress state for the pallet separation process, avoid separation according to fixed actions or preset sequences, and improve the rationality of pallet separation decisions.

[0017] 2. This invention predicts the load distribution change after the corresponding load transmission path is removed based on the degree of influence of each load transmission path, and generates a separation action sequence accordingly. During the separation process, the load transmission path and separation action sequence are continuously updated based on the new force response data, realizing dynamic closed-loop control of the pallet separation process. This effectively reduces the risk of pallet jamming and separation failure caused by local load concentration, and improves the stability, success rate and efficiency of pallet separation. Attached Figure Description

[0018] Figure 1 This is an overall flowchart of a tray separation control method for a tray destacking machine provided in an embodiment of the present invention; Figure 2This is a structural block diagram of a tray separation control system for a tray destacking machine provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the overall structure of a tray destacking machine provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of a load transfer path formation provided in an embodiment of the present invention; Figure 5 This is a comparison chart of the maximum load concentration for different candidate separation orders provided in an embodiment of the present invention. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0020] Example 1 provides a pallet separation control method for a pallet destacking machine, applied to the pallet separation process of the machine. The method first applies a trial excitation force to the pallet stack and acquires the force response data of the pallet stack. The amplitude of the trial excitation force is less than the minimum separation force required for separating a single layer of pallets. Then, based on the force response data, the load transfer path in the pallet stack is determined, and the influence of each load transfer path on the overall load transfer is determined. The load transfer path is formed by connecting pallet combinations with load transfer relationships according to the load transfer direction. Further, based on the degree of influence, the load distribution change after removing the corresponding load transfer path is predicted. Subsequently, a separation action sequence is generated based on the degree of influence and the corresponding load distribution change, and the pallet destacking machine is controlled to perform pallet separation according to the separation action sequence. During the separation process, the load transfer path is continuously updated based on the new force response data, and the separation action sequence is regenerated until pallet separation is completed.

[0021] Unlike existing pallet destacking machines that perform pallet separation according to fixed actions or preset sequences, this embodiment analyzes the load transmission path based on the actual stress state of the pallet stack and dynamically plans the separation action in conjunction with changes in load distribution. This allows the separation action to be adjusted according to changes in the stress state of the pallet stack, thereby reducing the probability of local load concentration during pallet separation and improving the stability and efficiency of pallet separation.

[0022] Example 2, Figure 1 The present invention discloses a tray separation control method for a tray destacking machine, comprising the following steps: S1, apply a trial excitation force to the pallet stack and obtain force response data, wherein the amplitude of the trial excitation force is less than the minimum separation force required for separating a single layer of pallets; In this embodiment, in order to avoid irreversible changes in the load inside the pallet stack due to direct pallet separation, the stress state of the pallet stack is first identified before the formal separation operation is performed.

[0023] Specifically, it includes the following steps: S11, the pallet destabilizing machine applies a tentative excitation force in a first direction to the pallet stack via a lifting mechanism or a clamping mechanism. The tentative excitation force is preferably a small load that does not change the overall stacking state of the pallet stack, with an amplitude less than the minimum separation force required to separate a single layer of pallets. The loading direction can be vertical, horizontal, or a combination of both. During the application of the tentative excitation force, the force detection device continuously collects the force response data of the pallet stack, forming the first force response data.

[0024] The force detection device is preferably a force sensor array disposed in each support area of ​​the destacking and stacking machine, including but not limited to pressure sensors disposed on the lifting mechanism, clamping force sensors disposed on the clamping mechanism, or thin-film pressure sensors disposed on the contact surface between the pallet stack and the destacking and stacking machine. The sampling frequency of the sensor array is preferably not less than 100Hz to ensure that the details of force changes during the excitation process can be captured.

[0025] The first force response data includes the force change curves of each pallet's corresponding position throughout the entire excitation process. The "corresponding position of each pallet" refers to the pallet area corresponding to the location of each measuring point in the sensor array. Since the sensor array is arranged on the contact surface between the pallet destacking machine and the pallet stack, different sensor measuring points correspond to specific areas on the bottom of different pallets. By the correspondence between the measuring point positions and the physical positions of the pallets, the force response data corresponding to each pallet can be determined.

[0026] S12, further compare the force change amplitude corresponding to each tray area. The force change amplitude is used to characterize the severity of the force fluctuation in that area under exploratory excitation, and can be calculated in the following way: (1) In equation (1), For the first The magnitude of force variation in each pallet area and The first The maximum and minimum force values ​​of each tray region during the excitation process in the first direction. Alternatively, the magnitude of the force change can be represented by the root mean square value of the force change or other characteristic quantities that can reflect the degree of force change.

[0027] Further comparison of the stress change amplitudes corresponding to each pallet area reveals that pallet areas with stress change amplitudes exceeding a preset threshold are identified as areas with significant stress changes. The preset threshold can be pre-set based on the pallet material and the number of stacked layers, and is preferably 1.2 to 2.0 times the average stress change amplitude of all pallet areas. Since these areas experience significant stress changes under external excitation, they indicate that they bear a greater load transfer responsibility and are crucial areas affecting the overall stress state of the pallet stack.

[0028] As another alternative implementation, instead of setting an absolute value threshold, the force change amplitude of all pallet areas can be sorted from largest to smallest, and the pallet areas with the highest preset ranking or the highest preset percentage can be identified as the pallet areas with larger force changes.

[0029] S13, control the pallet stacking machine to perform local load release on the pallet areas with significant stress changes. Local load release refers to reducing or eliminating the load on the target area while maintaining the load state of non-target areas unchanged. Local load release can be achieved through methods such as local lifting, local clamping release, local support adjustment, or local pushing, with the aim of changing only the load transmission state near the target area while maintaining the overall structural stability of the pallet stack.

[0030] After the partial load is released, a trial excitation force in a second direction is applied to the pallet stack. This second direction differs from the first direction—for example, if the first direction is vertical, the second direction is horizontal; or if the first direction is horizontal, the second direction is at an angle to the horizontal—to alter the load transfer state within the pallet stack, resulting in different response characteristics for different load transfer relationships. The amplitude of the second-direction excitation is also less than the minimum separation force required for the separation of a single-layer pallet, ensuring that no actual separation occurs during the detection process. The force detection device continuously collects the force response data of the pallet stack again to obtain the second force response data corresponding to the current pallet area.

[0031] After completing the second force response data acquisition for the pallet area, restore the load state of the area to the initial state, and then repeat the above steps of local load release and second direction excitation for the next pallet area with large force changes until all pallet areas with large force changes have been detected.

[0032] S14, compare the first force response data with the second force response data. For the first... After the first target pallet area is released, the first The difference in force change in the observed tray area during the two excitation processes is defined as: (2) In equation (2), For the first The magnitude of force change (reference response) of each tray area during the excitation process in the first direction. To release the first After the first target pallet area The amplitude of force change in each tray region during the second-direction excitation process. To release the first After the first target pallet area The difference in force variation in each pallet area.

[0033] When targeting the area After partial load release, if another tray area corresponding If the absolute value is large, it indicates that the tray With the target pallet There is a strong load transfer effect between them; conversely, if A smaller absolute value indicates a weaker load transfer effect between the two.

[0034] Based on the above analysis, a tray is defined. With tray The degree of influence of the forces between them is as follows: (3) In equation (3), Indicates release of tray rear tray The degree of force change reflects the change from the pallet To the tray The magnitude of the load transfer effect. This constitutes a force influence matrix. The elements in the matrix represent the degree of force influence between any two pallets.

[0035] S2, determine the load transfer path in the pallet stack based on the force response data, and determine the degree of influence of each load transfer path on the overall load transfer. The load transfer path is formed by connecting pallet combinations with load transfer relationships according to the load transfer direction. In this embodiment, S2 takes the stress influence between each pallet from the output of step S1, analyzes the load transfer relationship inside the pallet stack, determines the load transfer path in the pallet stack, and further evaluates the role of each load transfer path in the overall load transfer, providing a basis for subsequent load redistribution prediction.

[0036] like Figure 4 As shown, multiple parallel load transfer paths are formed inside the pallet stack through the contact points between the pallets. The load magnitude and transfer direction may differ for different paths. The specific steps for path construction are as follows: S21, assuming the pallet stack contains a total of Each pallet, based on the force influence matrix obtained in step S1 We then analyzed whether there was a load transfer relationship between each pallet.

[0037] For any two pallets and When the corresponding degree of force influence Greater than the preset association threshold At that time, determine the tray With tray There is a payload transfer relationship between them, and the pallet... and tray It is determined to be a load transfer tray assembly.

[0038] The associated threshold It can be set in advance according to the experiment, or it can be a certain proportion of the average value of all the influence of force, such as 1.2 to 1.5 times the average value.

[0039] After completing the screening of all pallet combinations, a set of all pallet combinations within the pallet stack that have load transfer relationships is obtained.

[0040] S22, for each load transfer pallet assembly Further analysis was conducted on the force response timing of the two trays during the exploratory excitation process.

[0041] Set up a tray The corresponding peak time of the force response is ,tray The corresponding peak time of the force response is .Compare and Size: like Greater than Then it is determined that the load is from the pallet. To the tray The direction of transmission is denoted as ; like Less than Then it is determined that the load is from the pallet. To the tray The direction of transmission is denoted as .

[0042] Since the upstream pallet usually experiences a change in force first during load transfer, and the downstream pallet responds subsequently, the direction of load transfer can be determined by the order of response times.

[0043] After completing the analysis of all pallet combinations, the load transfer directions within the pallet stack are obtained.

[0044] S23. Based on the load transfer directions obtained in step S22, multiple pallets with end-to-end connection relationships are sequentially connected to form a continuous load transfer path.

[0045] For example: pallet A → pallet B, pallet B → pallet C, pallet C → pallet D, thus forming a continuous load transfer path A → B → C → D.

[0046] If multiple pallet combinations are not continuously connected, they will form different load transfer paths.

[0047] After completing all connections, the complete set of load transfer paths in the pallet stack is obtained: (4) In equation (4), This represents the total number of load transfer paths.

[0048] S24, for each load transfer path, further determine the path's ability to stably bear the load transfer.

[0049] Because the overall load-bearing capacity of a path is limited by its weakest connection, known as the "barrel effect"—the insufficient transmission capacity of any link in the path will limit the maximum load that the entire path can transmit—this embodiment uses the minimum value of the force influence of each pallet assembly in the path as the load transmission capacity of the path.

[0050] Let the first The load transfer path includes The corresponding stress impact levels of each pallet combination are as follows: The load transfer capability of this load transfer path is defined as follows: (5) In equation (5), Indicates the first The load transfer capability of each load transfer path.

[0051] The above method avoids overestimating local weak connections and better reflects the actual load transfer characteristics. After completing the calculation of all paths, the system outputs each load transfer path and its corresponding load transfer capacity.

[0052] S25, In order to assess the importance of each load transfer path, each load transfer path is sequentially designated as the target load transfer path.

[0053] For the target load transfer path, the load transfer relationship corresponding to that path is only removed in the calculation model, without performing an actual separation operation. The "simulated removal" means deleting the tray combination connection edge corresponding to the target path in the load transfer network model, keeping the topology of the remaining paths unchanged, and then recalculating the load distribution state in the network based on mechanical equilibrium constraints.

[0054] After the target path is removed, the load originally borne by the target path is redistributed according to the load transfer capacity of each load transfer path connected to the target path. The redistribution process follows the principle of load conservation—the total load borne by the pallet stack remains unchanged before and after removal; only the load borne by each load transfer path changes.

[0055] After the redistribution is completed, the load values ​​that each load transfer path will re-accept are obtained.

[0056] Let the first The load borne by the load transfer path before the target path is simulated as follows: The simulated load after the target path is removed is Then its load change for: (6) in, This indicates that the path has taken on the new load (receiving the load transferred from the target path). This indicates that the load on this path has decreased. This indicates that the load along the path remains constant.

[0057] This step simulates the load values ​​that each load transfer path re-bears after the target path is removed. This data will be recorded and used as input data for subsequent predictions of load distribution changes after the target path is lifted.

[0058] S26, Based on the load changes obtained in step S25 To determine whether local load concentration occurs after load redistribution.

[0059] When the load change corresponding to a certain path Exceeding the preset concentration threshold When this occurs, the path is determined to enter a load concentration state. The preset concentration threshold... The preferred value is 1.5 times the average value of all positive load changes, or the standard deviation of all positive load changes.

[0060] Load transfer paths that are spatially adjacent and both located in a state of load concentration are merged to form a load concentration region. : (7) After completing all path analyses, the total load concentration area formed after the target load transfer path is removed is obtained.

[0061] S27, For the target load transfer path, based on the load concentration area determined in step S26, the following statistics are compiled: The sum of load increments corresponding to the load concentration area ; Number of pallets covered in the concentrated load area .

[0062] The larger the total load increment, the more loads need to be redistributed after the target path is removed, and the greater the role the target path plays in the overall load transfer. The fewer the number of covered trays, the more concentrated the load is, the higher the risk of local overload, and the easier it is to cause local jamming.

[0063] Therefore, the sum of load increments is used as the primary evaluation indicator: the larger the sum of load increments, the greater the impact of the target path. When the sum of load increments is the same, the path with fewer covered pallets is considered to have a greater impact.

[0064] After completing the analysis of all target load transfer paths, the overall impact of each load transfer path is obtained.

[0065] S3, based on the degree of impact, predict the change in load distribution after the corresponding load transfer path is removed; In this embodiment, S2 has already obtained the degree of influence corresponding to each load transfer path. However, the degree of influence only reflects the importance of each load transfer path to the overall load transfer, and cannot reflect how the load will be redistributed among the remaining load transfer paths after the load transfer path is removed. Therefore, this step, based on the degree of influence of the target load transfer path, further predicts the change in load distribution after the target load transfer path is removed, providing a basis for the subsequent generation of the separation action sequence.

[0066] This step includes: obtaining the load transfer capacity of the target load transfer path, determining the load transfer priority order based on the load transfer capacity and the current load percentage, reallocating the load according to the load transfer priority order, and determining the load percentage after reallocation.

[0067] S31, for each target load transfer path for which the influence degree calculation was completed in S2, read its corresponding load transfer capability. The load transfer capability is inherited from the calculation result of step S24 and is used to characterize the ability of the corresponding load transfer path to undertake load transfer.

[0068] Let the target load transfer path be denoted as The corresponding load transfer capability is The current load is .in, This indicates the load transfer capability of the target path. This indicates the current load on the target path.

[0069] Since the load it bears needs to be redistributed after the target load transfer path is removed, the currently borne load will be... As the load to be transferred.

[0070] S32, First determine the transfer path to the target load. The set of directly connected load transfer paths For each connection path Obtain the current load it is currently bearing. and corresponding load transfer capability .

[0071] Further calculate the current load percentage for each connection path: (8) In equation (8), Indicates the first The current load percentage of each load transfer path. The smaller the value, the greater the remaining carrying capacity of the path. The larger the value, the closer the path is to full load and the smaller the load margin.

[0072] The load transfer priority order is then determined according to the following rules: Prioritize the current load percentage Lower load delivery path; if the current load percentage If the load transfer capacity is similar (e.g., the difference is no more than 5%), then the load transfer capacity should be selected first. Larger load transfer path.

[0073] After sorting according to the above rules, the load transfer priority order is obtained. ,in For the transfer path with the target load Total number of directly connected paths.

[0074] S33, according to the determined load transfer priority order , transfer the target payload path Loads borne They are assigned to each connection path in sequence.

[0075] For the priority order, the first Connection path Its remaining bearing capacity is calculated as follows: (9) In equation (9), Indicates the first Connection path The load that it can continue to bear without exceeding its load-bearing capacity.

[0076] Let the remaining load that has not yet been assigned be... (Initial value) Then the load allocated to the current connection path is: (10) In equation (10), This indicates the actual load allocated to the current connection path.

[0077] After allocation is complete, update the remaining load: (11) If the updated residual load If the value is greater than 0, continue to allocate to the next connection path; if... If the value is 0, then load assignment ends.

[0078] After completing the above process, the load on each connection path is updated as follows: (12) Target path After being released, its load value is zero, that is .

[0079] In the above allocation process, the principle of load conservation is strictly followed, that is, the total load released after the target path is released is equal to the sum of the loads borne by each connecting path.

[0080] S34, After the load redistribution is completed, calculate the load percentage of each load transmission path after redistribution.

[0081] Total load borne by all load transfer paths This is the sum of the loads on all paths after redistribution. Since load conservation is satisfied, If the load is equal to the total load before redistribution (i.e., including the load before the target path is released), then the first... The load percentage after the load transfer path is redistributed is: (13) In equation (13), This indicates the percentage of load after redistribution, reflecting the load share of this path in the redistributed load delivery network.

[0082] The load proportions corresponding to each load transfer path are combined to form a new load distribution result, which serves as the load distribution change after the target load transfer path is removed.

[0083] S4, generate a separation action sequence based on the degree of impact and the corresponding load distribution changes, and control the destacking and stacking machine to perform separation operations according to the separation action sequence; In this embodiment, S2 determines the degree of influence of each load transfer path, and S3 predicts the load distribution changes after removing each load transfer path. Based on this, this step further determines the sequential execution relationship between each load transfer path, and generates multiple candidate separation sequences according to the sequential execution relationship. By simulating and evaluating each candidate separation sequence, the final separation action sequence is determined to reduce the risk of local load concentration and pallet stack instability during the separation process.

[0084] S41, the step of generating a separation action sequence based on the degree of influence and the corresponding load distribution change specifically includes the following steps: S41-1, for any two load transfer paths and Based on their respective degrees of influence and the changes in load distribution after the removal, the order of execution between the two is determined according to the following rules: Rule 1: When the path is terminated This led to the path When the load increment exceeds the preset safety threshold, it indicates Not capable of undertaking The load-bearing margin for the transferred load, if the first demolition... This will lead to Overload. Therefore, removal should be prioritized. This allows the load to be transferred or released first, before dismantling. That is, to determine Prior to Execution. The preset security threshold. Based on the load transfer capacity of the path A certain percentage is set.

[0085] Rule 2: When the path and If, during consecutive release, the predicted load concentration exceeds a preset concentration threshold, it indicates that releasing both paths consecutively will lead to excessive load concentration in a localized area, increasing the risk of pallet damage or jamming. Therefore, consecutive execution of both paths should be avoided. and Insert at least one other path between them, that is, determine. and Execution is discontinuous.

[0086] Rule 3: When the target load transfer path is released Subsequently, if the overall support of the pallet stack is compromised (e.g., the remaining paths cannot form a continuous load transfer path, or the total load transfer capacity of the remaining paths is lower than the preset proportion of the total load before release), it indicates that... This is a critical path for maintaining the overall stability of the pallet stack; premature removal could lead to instability or even collapse. Therefore, it should be scheduled as the last step, i.e., determined after [the event / event is completed]. Finally, execute.

[0087] In this step, the priority of the rules is as follows: Rule 3 takes precedence over Rule 1, and Rule 1 takes precedence over Rule 2. That is, first, the critical path that must be executed last is identified, then the order of execution among the remaining paths is determined, and finally, the restriction on consecutive execution is addressed.

[0088] Based on the execution order relationships determined above, multiple candidate separation sequences that satisfy all execution order relationships are generated. The execution order relationships include the following types: path Must precede path Execution; Path With path Cannot be executed consecutively; path It must be executed after all other paths.

[0089] Provided that all the above relationships are satisfied, paths not constrained by sequential relationships can be arranged in any order, thus forming multiple candidate separation orders.

[0090] S41-2, for each generated candidate separation order The release process of each load transfer path is simulated and executed in this order.

[0091] During the simulation, after each path is removed, the load distribution of the remaining paths is recalculated according to the method in step S3, and the corresponding load concentration is determined. After completing all removal steps for the candidate sequence, the maximum load concentration that occurs during the entire separation process is recorded. The maximum load concentration reflects the load distribution according to the candidate separation sequence. The most dangerous instantaneous state during the separation process – the smaller this value, the lower the peak local load generated by the sequence during separation, and the higher the safety.

[0092] like Figure 5 As shown, the maximum load concentration corresponding to all candidate separation sequences is compared, and the candidate separation sequence with the smallest value is selected as the final separation action sequence. The separation action sequence is output to the tray destacking machine control system to control the tray destacking machine to perform the separation operation of the corresponding tray area in sequence according to the separation action sequence.

[0093] S42, the control of the tray unpacking machine to perform the separation operation according to the separation action sequence includes the following steps: S42-1, the separation action sequence includes the execution order of multiple load transfer paths. According to the execution order, the load transfer path to be executed is selected in sequence, and its corresponding pallet area is determined as the current target separation area. The "load transfer path" physically corresponds to a pallet assembly area with a clear mechanical coupling relationship in the pallet stack; therefore, each load transfer path can be mapped to an independent working unit of the pallet destacking machine.

[0094] Let the current execution order be the first... The load transfer path is The corresponding target separation region is represented as: (14) In equation (14), For the first Each target separation region This is a mapping relationship from the path to the physical pallet area. This mapping is based on the construction result of the load transfer path and is determined by the spatial position (including the floor height and horizontal orientation) of the pallet combination contained in the path in the pallet stack.

[0095] S42-2, when the current target separation region is determined Then, the control unit performs a separation operation on the area. The separation operation includes, but is not limited to, at least one of the following: Partial lifting operation; partial clamping and releasing operation; partial pushing operation.

[0096] Among them, partial lifting operation refers to controlling the lifting mechanism of the destacking machine to separate the target area. The corresponding pallet is partially lifted, gradually reducing the contact pressure between that area and the adjacent pallet until the contact constraint is released. The local clamping release operation refers to controlling the clamping mechanism to release the clamping force on the target separation area, so that the constraint state of the area changes from controlled constraint to free state, thereby reducing the local load constraint.

[0097] Local pushing operation refers to applying a horizontal or oblique pushing force to the target separation area through a drive mechanism, causing a small relative displacement of the tray in that area, thereby breaking the local friction locking state and realizing the formation of separation conditions.

[0098] During the separation process, the force detection device continuously collects the force response data of the current pallet stack to determine whether the target separation area has been completely separated. When the contact force corresponding to the target separation area drops below a preset threshold, it is determined that the area has been completely separated.

[0099] S42-3: After the current target separation area is separated, the control system automatically switches to the next target separation area according to the sequence of separation actions, and repeats the operation of step S42-2 until all pallet areas corresponding to all load transfer paths are separated.

[0100] If the force response data of the current target separation area is detected to deviate from the expected range by more than the preset range during the separation process, the control system can trigger the update process from S1 to S4 as needed. That is, based on the current real-time force response data, the load transfer path is reconstructed, the degree of influence is assessed, the load distribution change is predicted, and the separation action sequence is regenerated to ensure the adaptability and safety of subsequent separation actions.

[0101] Once all target separation areas in the separation action sequence have been separated, the system determines that the pallet stack separation is complete. At this point, the separation control command output of the pallet stacking machine stops, completing the entire pallet stacking process.

[0102] S5 updates the load transfer path based on the force response data after the separation operation and regenerates the separation action sequence until the pallet separation is completed.

[0103] S4 has completed the current round of separation operations. Since the load transfer state of the pallet stack has changed after the separation operation, the original load transfer path may no longer accurately reflect the current stress state. Therefore, it is necessary to update the load transfer path based on the new stress response data and regenerate the separation action sequence to ensure the effectiveness of subsequent separation operations. The implementation method is the same as steps S1 to S4, and will not be repeated here.

[0104] Example 3: A tray separation control system for a tray destacking machine, such as... Figure 2 As shown, it includes: The excitation acquisition module is used to apply a tentative excitation force to the pallet stack and acquire force response data. The amplitude of the tentative excitation force is less than the minimum separation force required to separate a single layer of pallets. The path analysis module is used to determine the load transfer path in the pallet stack based on the force response data, and to determine the degree of influence of each load transfer path on the overall load transfer. The load transfer path is formed by connecting pallet combinations with load transfer relationships according to the load transfer direction. The load prediction module is used to predict the load distribution changes after the corresponding load transfer path is removed, based on the degree of impact. The motion planning module is used to generate a separation action sequence based on the degree of impact and the corresponding load distribution changes, and to control the destacking and stacking machine to perform separation operations according to the separation action sequence. The feedback update module is used to update the load transfer path based on the force response data after the separation operation and regenerate the separation action sequence until the pallet separation is completed.

[0105] Example 4, a destacking and stacking machine, such as Figure 3 As shown, it includes: Frame, lifting mechanism, clamping mechanism, drive mechanism, force detection device, processor and memory; The frame is used to support the various actuators and the pallet stack.

[0106] The lifting mechanism is mounted on the frame and is used to partially lift the pallet stack to achieve exploratory stimulation and pallet separation operations.

[0107] The clamping mechanism is located on both sides of the lifting mechanism and is used to clamp the target pallet, and cooperate with the lifting mechanism to complete the partial load release and pallet separation.

[0108] The drive mechanism is connected to the lifting mechanism and the clamping mechanism respectively, and is used to drive the lifting mechanism and the clamping mechanism to perform predetermined actions. The drive mechanism can be a servo motor, a hydraulic actuator or a pneumatic actuator.

[0109] The force detection device is positioned at the contact point between the pallet stack and the destacking machine to collect force response data of the pallet stack. The force detection device may include one or more combinations of pressure sensors, force sensor arrays, thin-film pressure sensors, or strain sensors.

[0110] The processor is electrically connected to the force detection device, the lifting mechanism, the clamping mechanism, and the drive mechanism, respectively, and is used to receive force response data and complete the tray separation control according to the control program in the memory.

[0111] The memory stores a computer program, which, when executed by a processor, causes the processor to perform the tray separation control method of the tray destacking machine described above.

[0112] In this embodiment, the destacking and stacking machine includes a frame, a lifting mechanism, a clamping mechanism, a pushing mechanism, a driving mechanism, a force detection device, a controller, and a memory.

[0113] The frame is used to install and support the various components; the lifting mechanism is used to lift the pallet stack to achieve relative separation between the pallets; the clamping mechanism is used to clamp or release the target pallet; the pushing mechanism is used to push the separated pallet to a designated position; and the drive mechanism is connected to the lifting mechanism, clamping mechanism and pushing mechanism respectively to drive the corresponding mechanism to perform the corresponding action.

[0114] The force detection device is used to acquire force response data of the pallet stack during the exploratory excitation and separation process. The force detection device may include force sensors, pressure sensors, displacement sensors, vibration sensors, or combinations thereof, and is used to detect the force, displacement, and vibration response information of the pallet stack under different working conditions.

[0115] The controller is connected to the force detection device, lifting mechanism, clamping mechanism, pushing mechanism and driving mechanism respectively. It is used to receive the force response data collected by the force detection device, determine the load transfer path in the pallet stack according to the force response data, determine the degree of influence of each load transfer path on the overall load transfer, predict the load distribution change after the corresponding load transfer path is removed, generate the separation action sequence, and control the destacking machine to perform the corresponding separation action.

[0116] The memory is used to store computer programs and data generated during operation; when the computer program is executed by the controller, the controller performs the tray separation control method for the tray destacking machine described in this embodiment of the invention.

[0117] The above formulas are all dimensionless calculations. The formulas are derived from software simulations based on a large amount of collected data to obtain the most recent real-world results. The preset parameters in the formulas are set by those skilled in the art according to the actual situation.

[0118] The above embodiments can be implemented, in whole or in part, by software, hardware, firmware, or any other combination thereof. When implemented using software, the above embodiments can be implemented, in whole or in part, in the form of a computer program product.

[0119] Those skilled in the art will recognize that the modules and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0120] In addition, the functional modules in the various embodiments of this application can be integrated into one processing module, or each module can exist physically separately, or two or more modules can be integrated into one module.

[0121] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0122] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A tray separation control method for a tray destacking machine, characterized in that, Includes the following steps: A trial excitation force is applied to the pallet stack, and force response data is obtained. The amplitude of the trial excitation force is less than the minimum separation force required to separate a single layer of pallets. The load transfer path in the pallet stack is determined based on the force response data, and the degree of influence of each load transfer path on the overall load transfer is determined. The load transfer path is formed by connecting pallet combinations with load transfer relationships according to the load transfer direction. Predict the load distribution changes after removing the corresponding load transfer path based on the degree of impact; Based on the degree of impact and the corresponding load distribution changes, a separation action sequence is generated, and the destacking and stacking machine is controlled to perform separation operations according to the separation action sequence. The load transfer path is updated based on the force response data after the separation operation, and the separation action sequence is regenerated until the pallet separation is completed.

2. The method according to claim 1, characterized in that, The process of applying a trial excitation force to the pallet stack and obtaining force response data includes: An exploratory excitation force in a first direction is applied to the pallet stack to obtain the first force response data; The pallet area with significant force changes is determined based on the first force response data; The load on the pallet area is partially released, and a trial excitation force in the second direction is applied to obtain the second force response data; Compare the first and second force response data to determine the degree of force influence between each pallet.

3. The method according to claim 2, characterized in that, Determining the load transfer path in the pallet stack based on the stress response data includes: The pallet combination with load transfer is determined based on the degree of force influence; The load transfer direction is determined based on the force response time sequence of each pallet combination. Connect the corresponding pallet combinations according to the load transfer direction to form a continuous load transfer path; The load transfer capacity is determined based on the degree of force influence corresponding to each continuous load transfer path, and each continuous load transfer path is output as the load transfer path.

4. The method according to claim 3, characterized in that, Determining the impact of each load transfer path on the overall load transfer includes: Each load transfer path is taken as the target load transfer path in turn, and the load redistribution process after the target load transfer path is removed is simulated to determine the load change corresponding to the remaining load transfer paths. The load concentration area is determined based on the load change corresponding to each load transfer path. The impact of the target load transfer path on the overall load transfer is determined based on the load increment and distribution range of the load concentration area.

5. The method according to claim 4, characterized in that, The method of predicting load distribution changes after removing the corresponding load transfer path based on the degree of impact includes: Obtain the load transfer capability corresponding to the target load transfer path; The priority order of load transfer is determined based on the load transfer capacity and current load percentage of each load transfer path connected to the target load transfer path. According to the load transfer priority order, the load borne by the target load transfer path is distributed to each load transfer path; The load percentage of each load transfer path after redistribution is determined as the load distribution change after the target load transfer path is removed.

6. The method according to claim 5, characterized in that, The step of generating a separation action sequence based on the degree of influence and the corresponding load distribution changes includes: Based on the degree of influence of each load transfer path and the change in load distribution after release, determine the sequential execution relationship between any two load transfer paths; Multiple candidate separation sequences are generated based on the sequential execution relationship between each load delivery path; Predict the load distribution changes corresponding to each candidate separation order and determine the corresponding maximum load concentration. The candidate separation sequence with the lowest maximum load concentration is determined as the separation action sequence.

7. The method according to claim 6, characterized in that, Determining the sequential execution relationship between any two load transfer paths includes: Predict the load increment of the second load transfer path after the first load transfer path is removed; When the load increment exceeds a preset threshold, the second load transfer path is determined to be executed before the first load transfer path. Predict the load concentration after any two load transfer paths are successively released; When the load concentration exceeds a preset threshold, it is determined that the two load transfer paths are not executed continuously. Predict the overall support status of the pallet stack after the target load transfer path is removed; When the prediction results indicate that the pallet stack loses stable support after the target load transfer path is removed, the target load transfer path is determined and executed last.

8. The method according to claim 7, characterized in that, The control mechanism for the stacking and separating of trays executes a separation operation according to a separation sequence, including: The current target separation region is determined based on the separation action sequence, and the target separation region is determined according to the spatial location corresponding to the load transfer path; Control the destacking and stacking machine to perform partial lifting, partial clamping and releasing, or partial pushing operations in the current target separation area; After completing the separation of the current target separation region, perform the separation operation of the next target separation region.

9. A tray separation control system for a tray destacking machine, characterized in that, include: The excitation acquisition module is used to apply a tentative excitation force to the pallet stack and acquire force response data. The amplitude of the tentative excitation force is less than the minimum separation force required to separate a single layer of pallets. The path analysis module is used to determine the load transfer path in the pallet stack based on the force response data, and to determine the degree of influence of each load transfer path on the overall load transfer. The load transfer path is formed by connecting pallet combinations with load transfer relationships according to the load transfer direction. The load prediction module is used to predict the load distribution changes after the corresponding load transfer path is removed, based on the degree of impact. The motion planning module is used to generate a separation action sequence based on the degree of impact and the corresponding load distribution changes, and to control the destacking and stacking machine to perform separation operations according to the separation action sequence. The feedback update module is used to update the load transfer path based on the force response data after the separation operation and regenerate the separation action sequence until the pallet separation is completed.

10. A destacking and stacking machine, characterized in that, include: Frame, lifting mechanism, clamping mechanism, drive mechanism, force detection device, processor and memory; The force detection device is used to acquire force response data of the pallet stack; The processor is connected to the force detection device, the lifting mechanism, the clamping mechanism and the driving mechanism respectively; The memory stores a computer program, which, when executed by a processor, causes the processor to perform the tray separation control method of the tray destacking machine as described in any one of claims 1 to 8.

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