Intelligent ton bag handling robot and automated handling method

Abstract

The application discloses a smart ton bag loading and unloading robot and an automatic loading and unloading method. The device is equipped with an X / Y / Z three-axis servo translation module, a visual component with a laser ranging function, an electromagnet pre-grabbing mechanism, a double mechanical self-locking load hook and an I-shaped tension sensor. A standardized forklift quick mounting interface is arranged, and power supply is layered and isolated, and a drag chain is fully protected by a cable. After the visual system identifies the sling coordinate, the three-axis linkage completes the magnetic pre-grabbing. After the tension sensor detects the effective load, the mechanical lock hook is triggered and the electromagnetic power supply is cut off. The unloading automatically opens the hook, and the whole process is realized without manual operation. The application can adapt to multiple specifications of ton bags and multiple hoisting equipment, and eliminates the safety hazards of high-altitude and dust working conditions without manual close-range operation. The laser vision is accurately aligned, the double mechanical self-locking prevents the hook from falling off, the load monitoring avoids misoperation, the electric control is anti-interference and resistant to dust corrosion, and is suitable for high-risk continuous transfer scenes such as chemical industry, thereby greatly reducing the cost and increasing the efficiency.

Description

Technical Field

[0001] This invention relates to the field of ton bag loading and unloading, and more particularly to intelligent ton bag loading and unloading robots and automatic loading and unloading methods. Background Technology

[0002] BOOM (Flexible Intermediate Bulk Container), also known as large-capacity flexible modular container, is the core packaging carrier for the storage and transportation of bulk materials in the industrial sector. It boasts numerous advantages, including lightweight construction, excellent structural strength, wear and tear resistance, and large loading capacity. It is widely used in the entire process of material stacking, transfer, and loading / unloading in various industries such as chemical raw materials, grains and oils, building materials powders, and mineral products. In scenarios such as large-scale logistics transfer, factory warehousing and unloading, and outdoor storage yard operations, BOOMs, with their wide adaptability and low storage and transportation costs, greatly improve the turnover efficiency of bulk materials, becoming an indispensable key consumable in the industrial production supply chain. However, in the core link of BOOM lifting and transfer, traditional supporting lifting equipment, after long-term field application, has gradually revealed many inherent technical defects and operational shortcomings, making it unable to meet the current development needs of intelligent, safe, and efficient industrial development. This seriously restricts the improvement of the quality and efficiency of BOOM material transfer operations. Specific technical bottlenecks and industry pain points are mainly reflected in the following three aspects.

[0003] First, the versatility of lifting tools is insufficient, resulting in poor adaptability and equipment compatibility. Most traditional ton bag lifting tools currently on the market have a fixed structural design with relatively simple parameters and specifications. They can only be used with standard ton bags of fixed size and lifting points, severely limiting their applicability. In actual industrial production, the size of ton bags, the position of the lifting straps, and the load-bearing capacity vary significantly across different industries and materials. On-site operations require frequent changes of the corresponding lifting tools based on the specifications of the ton bags to be transferred, significantly increasing the difficulty for operators, extending the preparation and equipment debugging time, and substantially increasing overall time and equipment maintenance costs. Simultaneously, the interface design of traditional lifting tools is rigid and lacks modular, adjustable, and flexible adaptability. They cannot quickly and efficiently connect with various mainstream lifting equipment such as forklifts, truck-mounted cranes, gantry cranes, and overhead cranes. Poor equipment adaptability makes it difficult to meet the needs of complex work sites and multi-equipment collaborative operations, greatly limiting the convenience and flexibility of on-site lifting operations and failing to adapt to modern material transfer scenarios involving multiple specifications, large quantities, and high frequencies.

[0004] Secondly, the high reliance on manual hooking and unhooking operations poses significant safety hazards and occupational health risks. Currently, the traditional loading and unloading operation of ton bag lifting equipment heavily relies on manual hooking and unhooking at heights to complete the entire lifting process, with extremely low levels of automation and automation. This operation mode not only requires a significant investment of manpower and resources, but also involves operators performing repetitive, high-intensity hooking and unhooking actions, resulting in extremely high labor intensity and continuously increasing labor and management costs for enterprises. More importantly, the on-site working environment is complex and variable, with some scenarios involving confined spaces, high-altitude operations, dusty environments, contact with corrosive media, and extreme temperatures. Close-range manual operation greatly increases the risk of accidents such as pinching injuries, falls, material collapses, and corrosive damage. Furthermore, prolonged exposure to harsh working environments can cause irreversible occupational health damage to the respiratory system and skin of operators. The shortcomings of manual intervention not only significantly increase the difficulty of on-site safety management but also become a core obstacle to the widespread adoption of fully automated and unmanned operations in ton bag lifting.

[0005] Third, the level of intelligence is low, and the accuracy and reliability of operations are insufficient. In special high-risk operation scenarios such as the handling of hazardous chemicals, flammable and explosive powders, and high-precision material transfer, traditional hoisting operations rely entirely on the operator's visual observation and manual judgment of alignment and unhooking. There are obvious blind spots, and they are easily affected by external factors such as operator fatigue, insufficient lighting, dust obstruction, and limited viewing angle, resulting in frequent problems such as alignment deviation, incomplete unhooking, and hoisting offset, which can easily lead to risks such as material spillage, equipment collision, and safety leaks. At present, the few modified hoisting tools on the market equipped with simple automatic unhooking and magnetic suction auxiliary systems can only adapt to low-frequency and simple operation needs. In complex logistics transfer scenarios with high frequency, continuity, high dust, and high corrosion in industry, the equipment's operational stability, environmental adaptability, and unhooking accuracy all have obvious shortcomings, with a high failure rate. The overall operational reliability cannot meet the stringent standards of large-scale industrial production.

[0006] In summary, the traditional ton-bag lifting equipment suffers from multiple technical bottlenecks, including poor adaptability, low safety, and insufficient intelligence. These bottlenecks have severely hampered the efficiency improvement and safety upgrades of bulk material lifting and transfer operations across various industries, making it difficult to align with the modern industrial development trends of cost reduction, efficiency improvement, inherent safety, and intelligent automation. Therefore, developing a new type of intelligent ton-bag lifting equipment with adaptive specification adjustment, fully automatic safe unhooking, intelligent remote control, and multi-condition adaptability is a key measure to overcome existing technical pain points and address shortcomings in lifting operations. It is also an urgent industry need to reduce costs and increase efficiency in material transfer, eliminate human safety risks, and promote the implementation of fully intelligent operations, possessing extremely high application value and market promotion significance.

[0007] February 25, 2025, ((TIAB = ("tonbagging machine; Three-axis moving system; Forklift; Electromagnet; Hook") )) AND (TIABC = ("tonbagging machine" OR "automatic bagging machine" OR "ton bag packaging equipment" OR "large bag handling system" OR "ton bag clamping device" OR "automatic big bag handling" OR "bulk bag automation" OR "ton bag machine") OR TIABC = ("three-axis moving system" OR "XYZ motion platform" OR "three-dimensional positioning system" OR "multi-degree-of-freedom mechanical structure" OR "automatic handling platform" OR "three-axis movement system" OR "XYZ positioning" OR "multi-axis mechanical structure") OR TIABC = ("electric forklift" OR "automated guided forklift" OR "AGV forklift" OR "intelligent forklift system" OR "material handling forklift" OR "electric forklift" OR "automated guided vehicle" OR A search was conducted in the China Patent Publication Database for the following patents: "material handlingforklift") OR "electromagnet" OR "magnetic suction device" OR "automatic adsorption system" OR "electromagnetic gripper" OR "magnetic clamp" OR "electromagnetic clamping device" OR "hook" OR "hook mechanism" OR "mechanical hook" OR "automatic hooking device" ), but no relevant literature was found. Summary of the Invention

[0008] Purpose of the invention: To provide a more effective intelligent ton bag loading and unloading robot and an automated loading and unloading method, the specific purpose of which is described in the several substantial technical effects in the specific implementation section.

[0009] To achieve the above objectives, the present invention adopts the following technical solution:

[0010] A smart ton bag loading and unloading robot, characterized in that the robot includes a support frame 24;

[0011] A visual component 1 is arranged on one side of the bracket 24;

[0012] The bracket 24 is provided with a bracket X-axis translation component and a Y-axis translation component. The Y-axis translation component includes a double Y-axis track and an X-axis translation component that can move as a whole on the double Y-axis track. The X-axis translation component is provided with a movable whole 23 that can move as a whole.

[0013] The movable assembly 23 is equipped with a load-bearing hook 25 and a Z-axis downward moving component 9.

[0014] The X-axis translation component 3 and the Y-axis translation component 5 are horizontally orthogonally assembled on the bracket 24, and the Z-axis downward movement component 9 is slidably assembled on the slide table movement assembly 23 of the X-axis translation component 3, which can be independently servo-displaced along the X, Y, and Z axes; the load-bearing hook 25 is a hook structure that can lock the ton bag;

[0015] The Z-axis lowering component 9 has a plate-like structure at the end of its power shaft that can move up and down. An electromagnet 7 is installed on the plate-like structure. The electromagnet 7 can attract the lifting rope with iron pieces on the ton bag. The electromagnet 7 is used to attract the metal patches pre-placed on the lifting rope of the ton bag to complete the pre-grabbing of the lifting rope. The forklift interface 4 is fixedly installed on the bracket 24 and is used to load the whole machine to the front of the forklift to realize the lifting and transportation of the whole machine. The vision component 1 is equipped with a laser ranging module and is fixed at the lower end of the Z-axis lowering component 9. It is used to collect the position of the lifting rope of the ton bag in real time and calculate the height distance between the equipment and the ton bag.

[0016] The X-axis translation component 3, Y-axis translation component 5, and Z-axis downward component 9 are respectively matched with the X-axis servo drive control part 15, Y-axis servo drive control part 16, and Z-axis servo drive control part 17. The three-axis servo drive independently controls the movement of the corresponding axis, and the three axes can be synchronously linked to complete the precise alignment of the ton bag lifting rope.

[0017] A further technical solution of the present invention includes a load-bearing hook locking assembly, which comprises a load-bearing hook component 2 and a load-bearing hook locking and limiting component 6. The load-bearing hook component 2 is composed of a first load-bearing hook part 255 and a second load-bearing hook part 256 hinged together. A drive wheel 252 is arranged on the power shaft of the power motor 251, and the drive wheel 252 is poweredly connected to a driven wheel 254. A gear 253 is arranged on the shaft on which the driven wheel 254 is mounted, and the gear 253 meshes with another gear. The first load-bearing hook part 255 and the second load-bearing hook part 256 are coaxially mounted on the two gears. Each of the two gears is coaxially mounted with a coaxial locking block 257.

[0018] The load-bearing hook locking and limiting component 6 is provided with a locking block 61 and a locking groove 62. After the first part 255 and the second part 256 of the load-bearing hook are fully closed, the locking block 61 is engaged with the locking groove 62 to form a mechanical self-lock. The coaxial locking block 257 cooperates with the gear 253 transmission mechanism to restrict the load-bearing hook from opening in the opposite direction and prevent it from disengaging during the lifting process. The locking block 61 is installed on the power shaft of the motor of the load-bearing hook locking and limiting component 6.

[0019] A further technical solution of the present invention is that it also includes a tension sensor 8, which is located between the load-bearing hook component 2 and the Z-axis downward movement component 9, for real-time detection of the lifting load of the ton bag; the electrical control integrated component includes an upper top plate 26, a camera controller 11, a switching power supply 13, an X-axis servo drive control part 15, a Y-axis servo drive control part 16, a Z-axis servo drive control part 17, a weighing transmitter 20, a main control hub 21, and a terminal block 22. All electrical components are neatly arranged in the cable tray 18 of the upper top plate 26. The drag chain 10 is used to store the cables 12 of the three-axis translation component; the electrical control integrated component is also equipped with a 48-volt DC contactor 14 and a step-down power supply 19 for layered power supply; the equipment frame is equipped with brackets 24 around its perimeter, and adjustable support feet are provided at the bottom. All moving component cables 12 are stored inside the drag chain 10, and the vision component 1 is fixedly assembled by a mounting bracket 101.

[0020] A further technical solution of the present invention is that drag chains 10 are mounted on both sides of the X-axis translation component 3 and the Y-axis translation component 5, and the power cables 12 and signal cables 12 of the three-axis motion are all housed inside the drag chains 10; the upper top plate 26 is provided with cable trays 18 to neatly fix the connecting cables 12 between the electronic control components.

[0021] A further technical solution of the present invention is that the electronic control integrated component adopts a layered power supply architecture: the switching power supply 13 supplies power to the vision component 1 and the camera controller 11; the 48-volt DC contactor 14 supplies power to the X-axis, Y-axis, and Z-axis servo drive control parts and the clamping power motor 251; the step-down power supply 19 provides low-voltage signal power to the main control Huichuan 21 and the weighing transmitter 20, and all power lines are uniformly housed in the cable tray 18 and connected to the terminal block 22.

[0022] A further technical solution of the present invention is that the tension sensor 8 is an I-shaped four-hole mounting structure, with the upper end connected to the sliding body 23 of the Z-axis downward moving component 9 slide table, and the lower end connected to the load-bearing hook component 2. The lifting load can be transmitted through the tension sensor 8 throughout the lifting process, and the weighing transmitter 20 can collect the load signal of the tension sensor 8 in real time and transmit it to the main control unit 21.

[0023] A further technical solution of the present invention is that the vision component 1 is equipped with a laser rangefinder to detect the vertical height between the whole machine and the ton bag. After the height reaches the standard, the vision component 1 can identify the plane coordinates of the lifting rope. The X-axis translation component 3 and the Y-axis translation component 5 drive the Z-axis downward component 9 to move above the lifting rope. The Z-axis downward component 9 pushes the electromagnet 7 to adhere to the metal patch of the lifting rope to complete the adsorption and gripping. The forklift interface 4 is a standardized quick-installation structure that can be adapted to the front-end mounting of different models of forklifts. The translation stroke of the X-axis translation component 3 and the Y-axis translation component 5 can cover the lifting rope spacing of various specifications of ton bags. The three-axis linkage adjustment can adapt to the operation of ton bags of different length and width dimensions.

[0024] A further technical solution of the present invention is that the main control unit 21 is interconnected with the vision component 1, the tension sensor 8, the electromagnet 7, the X-axis servo drive control unit 15, the Y-axis servo drive control unit 16, the Z-axis servo drive control unit 17, and the clamping power motor 251. After the tension sensor 8 detects an effective lifting load, the main control unit 21 can control the clamping power motor 251 to close the load-bearing hook component 2. After the load-bearing hook locking limit component 6 completes locking, the main control unit 21 cuts off the power supply to the electromagnet 7, and the load-bearing hook component 2 can mechanically bear the weight of the ton bag.

[0025] An automatic loading and unloading method for ton bags based on any of the above-described intelligent ton bag loading and unloading robots, characterized by the following steps: S1, Equipment mounting: The intelligent ton bag loading and unloading robot is fixed to the front end of a forklift via a forklift interface 4, and the forklift drives the entire machine to move above the ton bag to be transferred; S2, Height measurement and positioning: The laser rangefinder mounted on the vision component 1 detects the vertical height between the entire machine and the ton bag in real time, and the forklift finely adjusts the machine height to the effective range recognized by the vision component 1; S3, Lifting rope visual recognition: The vision component 1 acquires the image of the ton bag lifting rope, the main control unit Huichuan 21 calculates the plane coordinates of the lifting rope, and sends displacement commands to the X-axis servo drive control unit 15 and the Y-axis servo drive control unit 16; S4, Three-axis alignment magnetic attraction: The X-axis translation component 3 and the Y-axis translation component 5 work together to move the Z-axis downward movement component 9 to directly above the target lifting rope, and the Z-axis downward movement component 9 pushes the electromagnet 7 downward. The electromagnet 7 is energized and attracts the metal patch on the lifting rope, completing the pre-grabbing of the lifting rope; S5, Three-axis return to zero: X S6. Load detection and mechanical locking hook: The forklift lifts the whole machine, and the tension sensor 8 collects the lifting tension in real time. After detecting the effective ton bag load, the main control Huichuan 21 starts the clamping power motor 251. The clamping power motor 251 drives the gear through the active wheel 252 and the passive wheel 254 to drive the first part 255 and the second part 256 of the load-bearing hook to close. The locking groove 62 of the locking block 61 fits the coaxial locking block 257 to achieve locking, and completes the mechanical self-locking. Then the main control Huichuan 21 cuts off the power supply to the electromagnet 7. S7. Transfer and unloading: The forklift lifts the whole machine to the safe transfer height and travels to the target unloading position. The main control Huichuan 21 controls the clamping power motor 251 to run in reverse, driving the load-bearing hook component 2 to open and release the ton bag lifting rope, completing a single automatic ton bag loading and unloading operation.

[0026] A further technical solution of the present invention is that,

[0027] The camera controller is a camera industrial computer, model: SHIpcW631SA24207457;

[0028] The power switch is a 48V DC~24V DC 200W switching power supply;

[0029] The DC contactor is a 48V DC contactor;

[0030] The main controller is Huichuan PLCEASY521;

[0031] Vision component model: CBLETH5MLU;

[0032] Tension sensor model: ZMX0420SAA.

[0033] The present invention, employing the above technical solution, offers the following advantages over existing technologies: Strong adaptability: Equipped with an X / Y / Z three-axis servo linkage module, its stroke covers various ton bag lifting rope spacings. Combined with a standardized forklift quick-installation interface, it can adapt to multiple ton bags and various lifting equipment, eliminating the need for frequent changes in lifting tools and reducing maintenance costs. Fully automated operation with high safety: Laser vision combined with an electromagnet automatically adsorbs and pre-grabs the lifting rope. A dual mechanical self-locking hook with gears and locking blocks eliminates the need for manual close-range hooking and high-altitude hook removal. Even in the event of power failure or electromagnetic failure, the mechanical structure remains locked, preventing the risk of bags falling and mitigating occupational injuries in dusty or corrosive environments. Precise and reliable positioning: The vision component integrates laser ranging, eliminating blind spots for manual vision. Three-axis servo closed-loop precise alignment; a series-connected I-beam tension sensor detects the load in real time, only locking the hook when a valid load is identified, preventing accidental empty hook operation and adapting to high-risk chemical transport scenarios. Excellent stability under harsh working conditions: The electrical control adopts a three-level independent power supply to isolate current interference; all cables are stored in cable chains and cable trays to isolate dust corrosion; the electrical components of the whole machine are centrally and neatly arranged, resulting in a low equipment failure rate and suitability for high-frequency continuous industrial operations. Attached Figure Description

[0034] To further illustrate the present invention, the following description is provided in conjunction with the accompanying drawings:

[0035] Figure 1 and Figure 2 A three-dimensional diagram of the invention;

[0036] Figure 3 This is a structural diagram of the visual sensor for the invention;

[0037] Figure 4 This is a structural diagram of a tension sensor;

[0038] Figure 5 This is a structural diagram of the internal core components;

[0039] Figures 6-9 A three-dimensional diagram of the invention;

[0040] Figure 10 This is a side view of the invention.

[0041] The components include: 1. Vision component; 2. Load-bearing hook component; 3. X-axis translation component; 4. Forklift interface; 5. Y-axis translation component; 6. Load-bearing hook locking and limiting component; 7. Electromagnet; 8. Tension sensor; 9. Z-axis downward movement component; 10. Cable chain; 11. Camera controller; 12. Cable; 13. Switching power supply; 14. 48V DC contactor; 15. X-axis servo drive control section; 16. Y-axis servo drive control section; 17. Z-axis servo drive control section. ; 18. Cable tray; 19. Step-down power supply; 20. Weighing transmitter; 21. Main control unit; 22. Terminal block; 101. Mounting bracket; 23. Moving assembly; 24. Bracket; 61. Locking block; 62. Locking groove; 251. Clamping motor; 252. Drive wheel; 253. Gear; 254. Driven wheel; 255. First part of the load-bearing hook; 256. Second part of the load-bearing hook; 257. Coaxial locking block; 26. Top plate. Detailed Implementation

[0042] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," "outer," "top," and "bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication of two components. For those skilled in the art, the specific meaning of the above terms in the present invention can be understood according to the specific circumstances.

[0043] 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.

[0044] This patent provides multiple parallel solutions; the different descriptions represent improved solutions or parallel solutions based on the basic solution. Each solution has its own unique characteristics. Furthermore, the technical features involved in the different embodiments of the invention described below can be combined with each other as long as they do not conflict with each other. Fixing methods not described herein can be any type of fixing, such as threaded fixing, bolt fixing, or adhesive bonding.

[0045] The choice of materials used in an invention does not limit the scope of protection.

[0046] Example 1;

[0047] The embodiment described here is an independent solution. The solution is: an intelligent ton bag loading and unloading robot, characterized in that the robot includes a support frame 24; a vision component 1 is arranged on one side of the support frame 24; the support frame 24 is equipped with an X-axis translation component and a Y-axis translation component, the Y-axis translation component including a double Y-axis track, and also including an X-axis translation component capable of moving as a whole on the double Y-axis track, the X-axis translation component being equipped with a movable assembly 23 capable of moving as a whole; the movable assembly 23 is equipped with a load-bearing hook 25 and a Z-axis downward movement component 9; the X-axis translation component 3 and the Y-axis translation component 5 are horizontally orthogonally mounted on the support frame 24, and the Z-axis downward movement component 9 is slidably mounted on the sliding movable assembly 23 of the X-axis translation component 3, and can be independently servo-displaced along the X, Y, and Z axes; the load-bearing hook 25 is a hook structure capable of locking the ton bag; the Z-axis downward movement component 9... A plate-like structure is arranged at the end of the power shaft that can move up and down. An electromagnet 7 is installed on the plate-like structure. The electromagnet 7 can attract the lifting rope with iron plate on the ton bag. The electromagnet 7 is used to attract the metal patch on the ton bag lifting rope to complete the pre-grabbing of the lifting rope. The forklift interface 4 is fixedly installed on the bracket 24 and is used to load the whole machine to the front end of the forklift to realize the lifting and transportation of the whole machine. The vision component 1 is equipped with a laser ranging module and is fixed at the lower end of the Z-axis downward component 9. It is used to collect the position of the ton bag lifting rope in real time and calculate the height distance between the equipment and the ton bag. The X-axis translation component 3, Y-axis translation component 5, and Z-axis downward component 9 are respectively matched with the X-axis servo drive control part 15, Y-axis servo drive control part 16, and Z-axis servo drive control part 17. The three-axis servo drive independently controls the movement of the corresponding axis. The three axes can be linked synchronously to complete the precise alignment of the ton bag lifting rope.In contrast to the shortcomings of existing technologies, such as "traditional ton bag lifting devices are fixed single-specification structures with a narrow range of lifting point compatibility, requiring frequent changes of lifting devices, and having fixed interfaces that only adapt to a single lifting device. Furthermore, the entire process relies on manual close-range hooking, and manual alignment is susceptible to deviations caused by dust and light interference, resulting in poor safety and adaptability under harsh working conditions," this patent innovatively integrates a three-axis servo adjustable module—X-axis translation component 3, Y-axis translation component 5, Z-axis downward movement component 9, laser ranging vision component 1, electromagnet 7 pre-grabbing mechanism, and standardized forklift interface 4—within the bracket 24 frame. The Y-axis translation component 5 uses dual Y-axis tracks to support the X-axis translation component 3, which moves across the entire range. The three axes are independently controlled by servo drives and can be synchronously linked. The vision component 1 calculates the height and lifting rope coordinates in real time and automatically outputs displacement commands to drive the three axes to achieve precise alignment. This allows for adaptation to ton bags with different lifting point spacings and sizes without the need for manual changes of lifting devices. The standardized forklift interface 4... The machine enables rapid mounting of forklifts, and the 24-position bracket is designed for compatibility with other lifting equipment. The 7-electrode electromagnet automatically attracts the metal patch of the lifting rope to complete the pre-grab, eliminating the need for manual hook-up. Laser ranging eliminates blind spots. The machine simultaneously addresses all the core defects of existing technologies from multiple dimensions, including ton bag compatibility, equipment compatibility, unmanned grabbing, and precise positioning. The entire three-axis servo linkage + vision magnetic attraction structure achieves fully automatic alignment and grabbing through servo closed-loop control and magnetic attraction physical logic, which fully complies with the physical laws of mechanical transmission and electromagnetic attraction and has no logical contradictions.

[0048] Example 2;

[0049] The embodiment described here is a further improvement to Embodiment 1. The embodiment further includes a load-bearing hook locking assembly, which comprises a load-bearing hook component 2 and a load-bearing hook locking and limiting component 6. The load-bearing hook component 2 is composed of a first load-bearing hook part 255 and a second load-bearing hook part 256 hinged together. A drive wheel 252 is arranged on the power shaft of the clamping motor 251, and the drive wheel 252 is poweredly connected to a driven wheel 254. A gear 253 is arranged on the shaft on which the driven wheel 254 is mounted, and the gear 253 meshes with another gear. The first load-bearing hook part 255 and the second load-bearing hook part 256 are coaxially mounted on the two gears. Each of the two gears is coaxially mounted with a coaxial locking block 257. The load-bearing hook locking and limiting component 6 is provided with a locking block 61 and a locking groove 62. After the first load-bearing hook part 255 and the second load-bearing hook part 256 are fully closed, the locking block 61 engages with the locking groove 62. A mechanical self-locking mechanism is formed. The coaxial locking block 257, in conjunction with the gear 253, restricts the load-bearing hook from opening in the opposite direction, preventing it from disengaging during the lifting process. The locking block 61 is installed on the power shaft of the motor of the load-bearing hook locking and limiting component 6. Compared to the shortcomings of existing technologies, such as "simple magnetic lifting devices rely solely on electromagnetic force to support ton bags, which are prone to loosening and bag detachment when power is lost or dust gets stuck, lack a mechanical locking structure, pose a high risk for manual high-altitude hook removal, and lack a reverse limiting structure, making it easy for the lifting load to cause the hook to automatically open, leading to material leakage and safety accidents," this patent innovatively integrates a gear meshing transmission mechanism, a snap-fit ​​mechanical self-locking structure, and a coaxial reverse limiting block into a load-bearing hook locking component. The clamping power motor 251 drives the paired gear 253 through the driving wheel 252 and the driven wheel 254 to open and close the hinged first part 255 and second part 256 of the load-bearing hook. After the hook closes, the locking block 61 rigidly embeds into the locking groove 62 to form the first mechanical self-locking, and the coaxial locking block 257 restricts the gear 253 to rotate in the opposite direction to form the second anti-opening limiting. The dual mechanical structure is completely independent of the electromagnet 7. Even in the event of electromagnetic failure, power outage, or dust jamming, the mechanical structure can still rigidly lock the hook in the power supply circuit. During unloading, the motor drives the hook to open automatically in reverse, completely eliminating the need for manual high-altitude hook removal. The gear meshing and the rigid limit of the locking block groove both conform to the mechanical self-locking principle. The load tension will not drive the gear to rotate in reverse, eliminating the risk of hook detachment from the lifting process from a physical perspective and solving the defects of insufficient locking reliability and high safety hazards of manual hook removal in traditional lifting devices.

[0050] Example 3;

[0051] The embodiment described here is a further improvement to Embodiment 1. This embodiment further includes a tension sensor 8, located between the load-bearing hook component 2 and the Z-axis downward movement component 9, for real-time detection of the lifting load of the ton bag. The integrated electrical control assembly includes an upper top plate 26, a camera controller 11, a switching power supply 13, an X-axis servo drive control unit 15, a Y-axis servo drive control unit 16, a Z-axis servo drive control unit 17, a weighing transmitter 20, a main control hub 21, and terminal blocks 22. All electrical components are neatly arranged in the cable tray 18 of the upper top plate 26. The cable chain 10 is used to store the cables 12 of the three-axis translation component. The integrated electrical control assembly also includes a 48V DC contactor 14 and a step-down power supply 19 for layered power supply. The equipment frame is equipped with brackets 24 around its perimeter, and adjustable support feet are provided at the bottom. All moving component cables 12 are stored inside the cable chain 10. The vision component 1 is fixedly assembled via a mounting bracket 101. Compared to the shortcomings of existing technologies, such as "traditional lifting devices lack real-time load monitoring, are prone to false locking when magnetic attraction fails or the lifting rope is not attracted, leading to lifting failure; electrical control circuits are messy and exposed, allowing dust and corrosive media to directly corrode cables and electrical components; multiple voltage modules sharing a power supply line are prone to current interference; equipment has a high failure rate during continuous operation; and electrical components lack a proper storage structure, making maintenance difficult," this patent innovatively and non-obviously combines an I-shaped tension sensor 8 arranged in series along the load transmission path, a layered isolated power supply and control integrated component, and a cable protection structure for the drag chain 10. The tension sensor 8 completely transmits the entire lifting load, and the weighing transmitter 20 collects the tension signal in real time and uploads it to the main control unit 21. The system only performs the hook locking action when it recognizes the effective load, avoiding false locking of the empty hook. The top plate 26 centrally houses all electrical control components, the cable tray 18 neatly fixes the static wiring, and all three-axis motion cables are housed inside the drag chain 10 to prevent dust corrosion. The switch power supply 13, 48V DC contactor 14, and step-down power supply 19 are also included. Layered independent power supply isolates current interference between different modules of vision, servo motor, and main control sensor. The adjustable support feet at the bottom of bracket 24 ensure the equipment is placed horizontally and stably. Vision component 1 is securely assembled with mounting bracket 101. Load series detection, layered power supply isolation, and full cable enclosure protection all comply with the basic knowledge of electrical control and mechanical testing, solving the defects of traditional lifting tools such as lack of load monitoring, poor electrical control protection, and messy and easily damaged wiring.

[0052] Example 4;

[0053] The embodiment described here is a further improvement to embodiment one. For this embodiment, drag chains 10 are mounted on both sides of the X-axis translation component 3 and the Y-axis translation component 5. All the power cables 12 and signal cables 12 of the three-axis motion are housed inside the drag chains 10. The top plate 26 is provided with cable trays 18 to neatly fix the connecting cables 12 between the electronic control components. In contrast to the shortcomings of existing technologies, such as "traditional adjustable lifting devices with exposed motion axis cables, repeated bending and friction during three-axis reciprocating translation leading to easy damage, dust and corrosive materials directly adhering to cable joints, and the mixing and entanglement of motion and electrical control static circuits, resulting in frequent cable wear and short circuits and poor stability during long-term continuous operation," this patent innovatively and non-obviously arranges the drag chain 10 on both sides of the X-axis translation component 3 and Y-axis translation component 5 tracks. All power and signal cables 12 of the three axes are completely enclosed and housed inside the drag chain 10. The drag chain 10 constrains the bending trajectory of the cables, avoiding cable pulling and wear during translational movement. The upper top plate 26 is equipped with a matching cable tray 18. The static connection cables 12 between electrical control components are stored separately, realizing the orderly arrangement of moving and static cables in separate zones. Dust and corrosive media cannot directly contact the cable joints and cores. The flexible protection of the drag chain and the partitioned wiring of the cable trays are in line with the common sense of industrial equipment cable protection design, which greatly reduces the probability of line damage under dusty and highly corrosive working conditions, and solves the defects of traditional lifting tools cables being exposed and easily damaged and messy wiring.

[0054] Example 5;

[0055] The embodiment described here is a further improvement to Embodiment 1. Regarding this embodiment: the integrated electrical control components adopt a layered power supply architecture: the switching power supply 13 supplies power to the vision component 1 and the camera controller 11; the 48V DC contactor 14 supplies power to the X-axis, Y-axis, and Z-axis servo drive control parts and the clamping motor 251; the step-down power supply 19 provides low-voltage signal power to the main control unit 21 and the weighing transmitter 20; all power lines are uniformly housed in the cable tray 18 and connected to the terminal block 22. Compared to the shortcomings of existing technologies, such as "the improved automatic lifting device uses a unified power supply, and voltage fluctuations occur when the high-power servo motor and clamping motor start and stop, interfering with visual imaging and tension sensor signal acquisition, easily leading to identification misalignment and load data distortion; the power lines are not uniformly stored, and maintenance and component replacement are cumbersome"; this patent innovatively adopts a three-level hierarchical independent power supply architecture. The switching power supply 13 separately supplies the low-power visual imaging module, the 48V DC contactor 14 independently drives the high-power servo and clamping motor 251, and the step-down power supply 19 separately outputs a low-voltage stable power supply to the main control Huichuan 21 and the weighing transmitter 20 signal acquisition module. The voltage fluctuations when the high-power load starts and stops will not be transmitted to the visual and sensor signal circuits, ensuring stable and reliable visual recognition and load detection data. All power lines are uniformly stored in the cable tray 18 and centrally connected to the terminal block 22. The zoned power supply and centralized and orderly wiring conform to the electrical anti-interference design principle, solving the defects of traditional lifting devices that suffer from interference with sensor imaging due to shared power supply and difficult maintenance due to messy wiring.

[0056] Example 6;

[0057] The embodiment described here is a further improvement to Embodiment 1. Regarding this embodiment: the tension sensor 8 has an I-shaped four-hole mounting structure, with its upper end connected to the sliding body 23 of the Z-axis downward moving component 9, and its lower end connected to the load-bearing hook component 2. The lifting load can be transmitted through the tension sensor 8 throughout the entire lifting process. The weighing transmitter 20 can collect the load signal from the tension sensor 8 in real time and transmit it to the main control unit 21. Compared to the shortcomings of existing technologies, such as "simple weighing lifting devices with bypassed sensor arrangements that cannot fully transmit the entire lifting load, resulting in large deviations in load detection values, flimsy sensor installation structures, concentrated lifting force at localized points that are prone to deformation and damage, and delayed data acquisition that prevents linkage with the hook-locking logic," this patent innovatively and non-obviously employs an I-shaped four-hole tension sensor 8 arranged in series along the complete load transmission path. The upper four holes are fixedly connected to the movable unit 23, and the lower four holes are fixed to the load-bearing hook component 2. The entire lifting force of the ton bag passes completely through the tension sensor 8. The I-shaped structure disperses load stress, avoiding deformation due to single-point force. The weighing transmitter 20 synchronously collects tension data in real time and uploads it to the main control unit 21 immediately. The data has no delay and can be directly linked to the hook-locking control logic. The symmetrical installation of the four holes and the series load transmission fully comply with the mechanical stress dispersion and tension detection physical principles, simultaneously improving detection accuracy and structural strength, and solving the defects of traditional lifting devices such as load detection distortion, easy sensor damage, and delayed signal that prevents linkage control.

[0058] Example 7;

[0059] The embodiment described here is a further improvement to Embodiment 1. Regarding this embodiment: the vision component 1 has a built-in laser rangefinder for detecting the vertical height between the machine and the ton bag. Once the height is within the acceptable range, the vision component 1 can identify the plane coordinates of the lifting rope. The X-axis translation component 3 and the Y-axis translation component 5 drive the Z-axis downward movement component 9 to move above the lifting rope. The Z-axis downward movement component 9 pushes the electromagnet 7 to adhere to the metal patch of the lifting rope, thus completing the adsorption and gripping process. The forklift interface 4 is a standardized quick-installation structure, adaptable to the front-end mounting of different forklift models. The translation stroke of the X-axis translation component 3 and the Y-axis translation component 5 can cover the spacing of lifting ropes for various ton bag specifications. The three-axis linkage adjustment can adapt to the operation of ton bags of different lengths and widths. In contrast to the shortcomings of existing technologies, such as "traditional lifting devices lack laser rangefinder assistance, manual height judgment is prone to overshooting and collisions with ton bags, lifting points rely on manual alignment with limited specifications, and non-standard lifting device interfaces can only match a single type of forklift, unable to accommodate the transport of ton bags of various sizes," this patent innovatively combines laser rangefinder height detection, image coordinate recognition, a three-axis servo wide-range travel module, and a standardized quick-install forklift interface with a matching vision component 1. Laser rangefinder accurately calculates the vertical height of the machine relative to the ton bag, avoiding collisions during descent. The vision imaging outputs the plane coordinates of the lifting rope, and the X and Y axes automatically adjust the wide-range travel to adapt to various lifting rope spacings. The three-axis linkage adapts to ton bags of different lengths and widths. The standardized forklift interface 4 quick-install structure can directly match multiple forklift models, and the bracket 24... The reserved points are compatible with other hoisting equipment; laser ranging, image coordinate recognition, and servo stroke adjustment are all achieved based on the principles of photoelectric imaging and servo displacement, eliminating the need for manual adjustment of the lifting equipment. At the same time, it takes into account the compatibility of multiple equipment mounting, solving the defects of traditional lifting equipment such as easy collision during height alignment, limited compatibility with various specifications, and incompatible equipment interfaces.

[0060] Example 8;

[0061] The embodiment described here is a further improvement to Embodiment 4. In this embodiment, the main control unit 21 is interconnected with the vision component 1, the tension sensor 8, the electromagnet 7, the X-axis servo drive control unit 15, the Y-axis servo drive control unit 16, the Z-axis servo drive control unit 17, and the clamping motor 251. After the tension sensor 8 detects a valid lifting load, the main control unit 21 can control the clamping motor 251 to close the load-bearing hook component 2. After the load-bearing hook locking limit component 6 completes locking, the main control unit 21 cuts off the power supply to the electromagnet 7, allowing the load-bearing hook component 2 to mechanically bear the weight of the ton bag. Compared to the shortcomings of existing technologies, such as "simple magnetic automatic lifting devices lack load detection and linkage logic, perform hook locking actions even when no lifting rope is attached, pose safety hazards when lifting with an empty hook, rely entirely on electromagnetic force to support the ton bag, and directly detach the bag after power failure, lacking mechanical load switching logic and resulting in a broken automated control process," this patent innovatively and non-obviously establishes a closed-loop control logic with interconnected signals across all components of the main control unit, Huichuan 21. The main control unit, Huichuan 21, synchronously receives positioning signals from the vision component 1 and load signals from the tension sensor 8. Only when the tension sensor 8 identifies a valid ton bag load does it issue a command to drive the clamping motor 251 to close the load-bearing hook component 2 and complete mechanical self-locking. After locking, it automatically cuts off the power supply to the electromagnet 7, switching to independent mechanical support of the ton bag weight, eliminating the risk of bag detachment due to electromagnetic power failure. The closed-loop control logic of load detection-hook locking-electromagnetic hook disconnection conforms to the safety control design specifications for automated equipment, with no logical gaps in signal interconnection, solving the defects of traditional improved lifting devices that lack load linkage, rely entirely on electromagnetic load, and have safety vulnerabilities in the control process.

[0062] Example 9;

[0063] The embodiment described here is an independent solution. Regarding the solution: an automatic loading and unloading method for ton bags based on any of the aforementioned intelligent ton bag loading and unloading robots, characterized by the following steps: S1, Equipment mounting: The intelligent ton bag loading and unloading robot is fixed to the front end of a forklift via forklift interface 4, and the forklift moves the entire robot above the ton bag to be transferred; S2, Height measurement and positioning: The laser rangefinder mounted on the vision component 1 detects the vertical height between the entire robot and the ton bag in real time, and the forklift fine-tunes the robot height to the effective range recognized by the vision component 1; S3, Rope visual recognition: The vision component 1 acquires an image of the ton bag's rope, the main control unit 21 calculates the rope's planar coordinates, and sends displacement commands to the X-axis servo drive control unit 15 and the Y-axis servo drive control unit 16; S4, Three-axis alignment magnetic attraction: The X-axis translation component 3 and the Y-axis translation component 5 work together to move the Z-axis downward component 9 directly above the target rope, and the Z-axis downward component 9 pushes the electromagnet 7 downward. S5. Three-axis zeroing: X-axis translation component 3, Y-axis translation component 5, and Z-axis downward component 9 synchronously reset to the equipment origin position; S6. Load detection and mechanical locking hook: The forklift lifts the whole machine, and the tension sensor 8 collects the lifting tension in real time. After detecting the effective ton bag load, the main control Huichuan 21 starts the clamping power motor 251. The clamping power motor 251 drives the gear through the active wheel 252 and the passive wheel 254 to drive the first part 255 and the second part 256 of the load-bearing hook to close. The locking groove 62 of the locking block 61 matches the coaxial locking block 257 to achieve locking, and complete the mechanical self-locking. Then the main control Huichuan 21 cuts off the power supply to the electromagnet 7; S7. Transfer and unloading: The forklift lifts the whole machine to the safe transfer height and travels to the target unloading position. The main control Huichuan 21 controls the clamping power motor 251. Reverse rotation drives the load-bearing hook component 2 to open and release the ton bag lifting rope, completing a single automatic ton bag loading and unloading operation.Compared to the shortcomings of existing technologies, such as the traditional ton bag loading and unloading process relying entirely on manual hooking, lifting, and unhooking, which is cumbersome, labor-intensive, prone to material collisions during manual positioning, lacks load verification steps, lacks mechanical locking hook switching for magnetic lifting devices, and is prone to bag detachment due to electromagnetic failure during transfer, and lacks standardized fully automated operation processes suitable for automated production lines, this patent innovatively constructs a seven-step fully automated closed-loop loading and unloading process: mounting, distance measurement and identification, three-axis magnetic gripping, zeroing, load verification, mechanical locking hook, and transfer and unloading. It utilizes laser vision positioning to replace manual height and lifting point judgment, three-axis servo linkage to automatically complete the magnetic pre-grip of the lifting rope, and three-axis zeroing to avoid friction between moving parts and the ton bag during transfer. A load verification process is added using a tension sensor (8), and mechanical self-locking and power cut-off of the electromagnet (7) are performed only under effective load. No close-range human intervention is required throughout the process, and the hook releases automatically upon unloading. The entire process strictly follows the sequence of "positioning - gripping - verification and locking - transfer - unloading". The industrial hoisting safety operation logic relies on the matching of equipment hardware structure with corresponding physical and electrical control principles at each step. The process has no logical conflicts, completely avoids the safety and efficiency defects caused by manual operation, and is suitable for unmanned, automated, and continuous transfer conditions.

[0064] Example 10;

[0065] The embodiment described here is a further improvement to Embodiment Nine; for this embodiment: the camera controller is a camera industrial computer, model: SHIpcW631SA24207457; the power switch is a 48V DC~24V DC 200W switching power supply; the DC contactor is a 48V DC contactor; the main controller is Huichuan PLCEASY521; the vision component model is CBLETH5MLU; the tension sensor model is ZMX0420SAA. In contrast to the shortcomings of existing technologies, such as "commonly available improved automatic lifting devices use general-purpose low-computing-power industrial control systems, ordinary sensors, and non-standard power supply components, resulting in slow visual imaging processing speed, insufficient load detection accuracy, unstable power supply to high-power servo motors, high component failure rates under harsh working conditions, and a lack of matching standardized component sets, making equipment debugging and spare parts replacement difficult," this patent innovatively and non-obviously addresses the entire automated loading and unloading process by matching a complete set of dedicated standardized components. It selects a dedicated camera industrial control computer (SHipcW631SA24207457) to ensure high-speed processing of laser vision images, a dedicated 48V DC to 24V DC 200W switching power supply paired with a 48V DC contactor to stably supply the high-power loads of the servo and clamping motors, an Inovance EASY521PLC as the main controller matching the servo drive communication protocol, a CBLETH5MLU vision component adapted to laser ranging and imaging requirements, and a ZMX0420SAA... The tension sensor is compatible with the heavy load detection range of ton bags; the parameters of the complete set of components are mutually matched, and the computing power, power supply, detection range and equipment three-axis motion, magnetic gripping and mechanical locking hook process are fully compatible. There are no problems such as recognition delay, insufficient power supply and load detection distortion caused by component parameter mismatch. The unified and standardized component models greatly reduce the difficulty of equipment debugging and subsequent spare parts maintenance, and solve the defects of traditional lifting tools such as messy component selection, poor working condition adaptability and cumbersome maintenance.

[0066] Currently, most traditional ton bag lifting devices on the market have a fixed structure design with relatively simple parameters and specifications. They can only be used with standard ton bags of fixed size and with fixed lifting points, severely limiting their adaptability to various scenarios. In actual industrial production, the size of ton bags, the position of the lifting straps, and the load-bearing capacity vary greatly depending on the industry and the materials being transported. During on-site operations, it is necessary to frequently change the corresponding lifting device according to the specifications and models of the ton bags to be transported. This not only significantly increases the difficulty of the operation for operators but also prolongs the time for lifting preparation and equipment debugging, significantly increasing the overall time cost and equipment maintenance cost. At the same time, the interface design of traditional lifting devices is fixed and simple, lacking a modular and adjustable flexible adaptable structure. It cannot be quickly connected and efficiently compatible with various mainstream lifting equipment such as forklifts, truck-mounted cranes, gantry cranes, and overhead cranes. Poor equipment adaptability makes it difficult to meet the needs of complex work sites and multi-equipment collaborative operations, greatly limiting the convenience and flexibility of on-site lifting operations and failing to adapt to modern material transfer scenarios with multiple specifications, large quantities, and high frequency.

[0067] This invention addresses the shortcomings of existing technologies, such as "narrow compatibility of fixed single-specification lifting devices with ton bags, frequent replacement of lifting devices, and fixed equipment interfaces that cannot be compatible with various types of lifting equipment." This patent innovatively and non-obviously integrates the three-axis servo adjustable motion module's X-axis translation component 3, Y-axis translation component 5, and Z-axis downward movement component 9 with a standardized forklift interface 4 into the same intelligent ton bag loading and unloading robot frame, thus completely solving the versatility problem from the two dimensions of ton bag specification adaptation and lifting equipment compatibility.

[0068] The principle of multi-specification ton bag adaptive adaptation is as follows: X-axis translation component 3 and Y-axis translation component 5 are horizontally orthogonally assembled on bracket 24. The dual Y-axis rail carries the X-axis translation component 3, which can move in the entire range. The X-axis slide carries the Z-axis downward component 9, which can be raised and lowered independently. The three axes are independently driven by X-axis servo drive control unit 15, Y-axis servo drive control unit 16, and Z-axis servo drive control unit 17, respectively. The three axes can be synchronously linked to complete the precise adjustment of any plane coordinates and height. The X and Y axis translation strokes cover the spacing of most ton bag lifting ropes on the market. The vision component 1 is equipped with a laser ranging module to identify the coordinates of the ton bag lifting ropes of different lengths, widths, and lifting point positions in real time, and automatically output displacement commands to adjust the position of the three axes. It can adapt to ton bags of different sizes and different lifting point layouts without the need for manual replacement of any lifting accessories. Corresponding workflow: S3 Sling visual recognition step, the main controller Huichuan 21 automatically calculates the three-axis displacement based on the sling coordinates collected by vision component 1. S4 Three-axis alignment magnetic attraction step automatically completes the sling alignment, eliminating the need for traditional lifting tool replacement and manual debugging steps, greatly shortening the lifting preparation time and reducing equipment maintenance and spare parts procurement costs.

[0069] The machine is compatible with various lifting equipment. The frame 24 has a standardized quick-installation structure and a forklift interface 4, which can be directly mounted to the front of the forklift to complete the lifting and transportation of the whole machine. At the same time, the whole machine is a modular integrated frame structure, and the frame 24 has reserved universal installation points, which can be quickly connected and mounted to mainstream lifting equipment such as truck cranes, gantry cranes, and overhead cranes. This breaks through the compatibility limitations of traditional single fixed interfaces of lifting tools and is suitable for multi-equipment collaboration and high-frequency transportation conditions in complex sites.

[0070] Currently, the traditional loading and unloading operation of ton bag lifting equipment relies heavily on manual hooking and unhooking at heights to complete the entire lifting process, with extremely low levels of automation and automation. This operation mode not only requires a significant investment of manpower and resources, but also involves operators performing repetitive, high-intensity hooking and unhooking actions, resulting in extremely high labor intensity and continuously driving up labor and management costs for enterprises. More importantly, the on-site working environment is complex and variable, with some scenarios involving confined spaces, working at heights, dusty environments, contact with corrosive media, and extreme high and low temperatures. Manual close-range operation greatly increases the risk of accidents such as pinching injuries, falls, material collapses, and corrosive damage. Furthermore, prolonged exposure to harsh working environments can cause irreversible occupational health damage to the respiratory system and skin of operators. The shortcomings of manual intervention not only significantly increase the difficulty of on-site safety management but also become a core obstacle to the widespread adoption of fully automated and unmanned operations in ton bag lifting.

[0071] This invention addresses the shortcomings of existing technologies, which rely entirely on manual close-range hooking and unhooking, resulting in high labor costs, potential personal injury in high-altitude / harsh working conditions, and the inability to achieve unmanned operation. This patent innovatively and non-obviously combines a vision component 1, an electromagnet 7 pre-grabbing mechanism, and a motor-driven self-locking load-bearing hook component 2 to construct a fully unmanned grabbing-locking-unhooking closed-loop mechanism. This eliminates the need for close-range manual intervention, completely eradicating the safety and occupational health risks associated with manual operation.

[0072] The fully automated rope pre-grabbing system eliminates the manual hooking process. The Z-axis lowering component 9 is equipped with an electromagnet 7 at the end of the power shaft, and metal patches are pre-placed on the ton bag rope. In the operation process S2-S4, after the vision component 1 completes height measurement and rope coordinate recognition, the three-axis linkage drives the electromagnet 7 to move precisely above the rope. The Z-axis lowering component 9 descends to make the electromagnet 7 fit the metal patch. After being energized, the rope pre-grabbing is completed by magnetic force. The entire rope picking process is fully automated, eliminating the need for personnel to bend over or reach close to the hook, thus avoiding the risks of pinching, material collapse, and compression.

[0073] The mechanical self-locking load-bearing hook automatically locks, eliminating the need for manual unhooking at height. Load-bearing hook component 2 consists of a first part 255 and a second part 256 hinged together, driven by a clamping power motor 251 via a drive wheel 252, gear 253, and driven wheel 254. The matching load-bearing hook locking and limiting component 6 is equipped with a locking block 61 and a locking groove 62. In process S6, after the tension sensor 8 detects a valid lifting load, the main control unit 21 automatically starts the clamping power motor 251 to close the load-bearing hook. The locking block 61 engages with the locking groove 62, forming a mechanical self-lock. The coaxial locking block 257 restricts the load-bearing hook from opening in the opposite direction. The entire lifting process relies on the mechanical structure to support the ton bag. After locking the hook, the power supply to the electromagnet 7 is cut off. During unloading (S7 step), the main control unit 21 reverses the drive of the clamping power motor 251 to automatically open the load-bearing hook and release the lifting rope. The entire process requires no manual unhooking at height, preventing falls from height.

[0074] Unmanned operation adapts to harsh working conditions and eliminates occupational health hazards. The entire set of grabbing, hooking, and unloading actions are controlled by the Huichuan 21 fully automatic logic controller. Operators only need to remotely control the forklift to move the whole machine without having to enter the dusty, corrosive, high and low temperature narrow working areas for close operation. This avoids irreversible occupational health problems such as dust inhalation, media corrosion, and high and low temperature skin damage from the source. At the same time, the entire set of equipment realizes unmanned operation of the ton bag hoisting process, which significantly reduces the input of manpower, reduces the company's human resource management costs, and removes obstacles to the implementation of automated production lines.

[0075] In special and high-risk operation scenarios such as the transfer of hazardous chemicals, flammable and explosive powders, and high-precision materials, traditional hoisting operations rely entirely on operators' visual observation and manual judgment for alignment and unhooking. This presents significant blind spots and is highly susceptible to interference from external factors such as operator fatigue, insufficient lighting, dust obstruction, and limited viewing angles. This frequently leads to problems such as alignment deviations, incomplete unhooking, and hoisting offsets, potentially causing material spillage, equipment collisions, and safety leaks. Currently, the few modified hoisting tools on the market equipped with simple automatic unhooking and magnetic auxiliary systems are only suitable for low-frequency, simple operational needs. In complex industrial logistics transfer scenarios characterized by high frequency, continuity, high dust levels, and high corrosiveness, the equipment exhibits significant shortcomings in operational stability, environmental adaptability, and unhooking accuracy, resulting in a high failure rate. Overall operational reliability cannot meet the stringent standards of large-scale industrial production.

[0076] This invention addresses the shortcomings of existing technologies: "relying on human eye for manual alignment is susceptible to environmental interference and deviations, simple automatic unhooking mechanisms have poor stability under complex working conditions, and the lack of load monitoring function makes them prone to lifting failures and leaks." This patent innovatively and non-obviously integrates a laser vision positioning module, an I-shaped tension sensor 8, a gear-driven mechanical self-locking load-bearing hook, and a layered isolation electrical control integrated component to achieve four intelligent and reliable guarantees: precise visual alignment, real-time load monitoring, dual mechanical anti-unhooking, and stable operation in high-dust and corrosive environments.

[0077] Laser vision composite positioning eliminates blind spots in human vision and improves alignment accuracy. Vision component 1 integrates a laser ranging module and an image recognition unit, driven by an independent camera controller 11. Step S2: Laser ranging accurately calculates the vertical height of the entire machine and the ton bag, avoiding height misjudgments caused by light and dust obstruction. Step S3: Visual imaging acquires the plane coordinates of the lifting rope, and the main controller Huichuan 21 calculates and generates precise three-axis displacement commands. The servo motor close-loop control precisely moves the X / Y / Z axes, eliminating alignment offset caused by human fatigue and limited viewing angle. It also prevents material spillage, hazardous material leakage, and equipment collisions caused by misalignment of the lifting rope, making it suitable for high-requirement and high-risk transportation scenarios such as chemical and flammable / explosive materials.

[0078] The tension sensor monitors the load in real time and links with the hook locking logic to improve operational safety and reliability. The I-shaped four-hole tension sensor 8 is installed between the mobile assembly 23 and the load-bearing hook component 2 to completely transmit the entire lifting load. The matching weighing transmitter 20 collects tension data in real time and uploads it to the main control unit 21. The system is set with load threshold logic. The main control unit 21 will only start the clamping motor 251 to complete the mechanical hook locking when the tension sensor 8 identifies a valid ton bag load. The hook locking action will not be performed under no-load, magnetic attraction failure, or sling not adhering conditions, avoiding accidental locking of the empty hook and lifting failure due to sling detachment. Compared with the simple magnetic attraction release mechanism on the market, the addition of load judgment closed-loop logic significantly reduces the probability of failure.

[0079] The dual mechanical self-locking structure of gears and limit blocks prevents accidental disengagement under complex working conditions. The load-bearing hook adopts a dual mechanical self-locking mechanism of gear 253 meshing transmission and locking block 61 groove 62 engagement: after the power motor 251 drives the gear set to close the hook, the locking block 61 rigidly embeds into the locking groove 62, and the coaxial locking block 257 restricts the rotation of the gear in the opposite direction. Under extreme working conditions such as power failure, electromagnetic failure, and dust jamming, the mechanical structure can still keep the hook closed, and there will be no problem of incomplete disengagement or accidental hook release. Unlike the improved lifting tools that only rely on magnetic attraction and electromagnetic locking, it is not affected by dust and corrosive media, and is suitable for high-frequency continuous industrial operation scenarios.

[0080] Layered isolation of integrated electrical control and cable protection enhances equipment stability under harsh operating conditions. The integrated electrical control components are powered independently in layers: a switching power supply 13 supplies power to the vision component 1, a 48V DC contactor 14 drives the servo and clamping motors, and a step-down power supply 19 provides low-voltage signal power to the main control and sensors, avoiding current interference between different modules. All power and signal cables 12 are uniformly housed inside the cable carriers 10 on both sides of the X / Y axis, with the top plate 26 and cable trays 18 neatly fixing the electrical control circuitry, preventing dust and corrosive media from directly corroding cable joints and electrical components. Physical isolation between the machine's moving parts and electrical control areas significantly reduces equipment failure rates under dusty and highly corrosive continuous operation, meeting the stringent reliability standards of large-scale industrial continuous production.

[0081] This invention addresses the shortcomings of traditional lifting tools in terms of versatility through a three-axis servo adaptive adjustment module; visual magnetic fully automatic grasping combined with a motor-driven mechanical self-locking load-bearing hook eliminates all manual close-range operation, thus eliminating safety and occupational health risks; laser vision precise positioning, real-time load monitoring, dual mechanical self-locking, and a protective layered electronic control system comprehensively improve intelligent precision and operational reliability under complex working conditions, fully covering the three core technical deficiencies of existing ton bag lifting tools, and meeting the industry's needs for cost reduction and efficiency improvement, inherent safety, and fully intelligent unmanned operation of ton bag transportation.

[0082] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claims.

Claims

1. An intelligent ton bag loading and unloading robot, characterized in that, The robot includes a support frame (24); A visual component (1) is arranged on one side of the bracket (24); The bracket (24) is provided with a bracket X-axis translation component and a Y-axis translation component. The Y-axis translation component includes a double Y-axis track and an X-axis translation component that can move as a whole on the double Y-axis track. The X-axis translation component is provided with a movable whole (23) that can move as a whole. The movable assembly (23) is equipped with a load-bearing hook (25) and a Z-axis downward moving component (9); The X-axis translation component (3) and the Y-axis translation component (5) are horizontally orthogonally mounted on the bracket (24), and the Z-axis downward component (9) is slidably mounted on the slide table moving assembly (23) of the X-axis translation component (3), and can be independently servo-displaced along the X, Y, and Z axes; the load-bearing hook (25) is a hook structure that can lock the ton bag; The Z-axis downward moving part (9) has a plate-shaped structure at the end of the power shaft that can move up and down. An electromagnet (7) is installed on the plate-shaped structure. The electromagnet (7) can attract the lifting rope with iron plate on the ton bag. The electromagnet (7) is used to attract the metal patch on the lifting rope of the ton bag to complete the pre-grabbing of the lifting rope. The forklift interface (4) is fixedly installed on the bracket (24) and is used to load the whole machine to the front of the forklift to realize the lifting and transportation of the whole machine. The vision component (1) is equipped with a laser ranging module and is fixed at the lower end of the Z-axis downward moving part (9) to collect the position of the lifting rope of the ton bag in real time and calculate the height distance between the equipment and the ton bag. The X-axis translation component (3), Y-axis translation component (5), and Z-axis downward component (9) are respectively matched with the X-axis servo drive control part (15), Y-axis servo drive control part (16), and Z-axis servo drive control part (17). The three-axis servo drive independently controls the movement of the corresponding axis, and the three axes can be synchronously linked to complete the precise alignment of the ton bag lifting rope.

2. The intelligent ton bag loading and unloading robot as described in claim 1, characterized in that, It also includes a load-bearing hook locking assembly, which includes a load-bearing hook component (2) and a load-bearing hook locking and limiting component (6). The load-bearing hook component (2) is composed of a first load-bearing hook part (255) and a second load-bearing hook part (256) hinged together. A drive wheel (252) is arranged on the power shaft of the clamping power motor (251), and the drive wheel (252) is powered to the driven wheel (254). A gear (253) is arranged on the shaft on which the driven wheel (254) is mounted. The gear (253) meshes with another gear. The first load-bearing hook part (255) and the second load-bearing hook part (256) are coaxially mounted on the two gears. Each of the two gears is coaxially mounted with a coaxial locking block (257). The load-bearing hook locking and limiting component (6) is provided with a locking block (61) and a locking groove (62). After the first part (255) and the second part (256) of the load-bearing hook are fully closed, the locking block (61) is inserted into the locking groove (62) to form a mechanical self-lock. The coaxial locking block (257) cooperates with the gear (253) transmission mechanism to restrict the load-bearing hook from opening in the opposite direction and prevent it from coming off during the lifting process. The locking block (61) is installed on the power shaft of the motor of the load-bearing hook locking and limiting component (6).

3. The intelligent ton bag loading and unloading robot as described in claim 1, characterized in that, It also includes a tension sensor (8), which is located between the load-bearing hook component (2) and the Z-axis downward movement component (9) for real-time detection of the lifting load of the ton bag; the electrical control integrated component includes an upper top plate (26), a camera controller (11), a switching power supply (13), an X-axis servo drive control part (15), a Y-axis servo drive control part (16), a Z-axis servo drive control part (17), a weighing transmitter (20), a main control hub (21), and wiring terminals (22). All electrical components are neatly arranged in the cable tray (18) of the upper top plate (26), and a drag chain (10) is used to store the cable (12) of the three-axis translation component; the electrical control integrated component also has 48 The DC contactor (14) and step-down power supply (19) are supplied in layers; the equipment frame is equipped with brackets (24) around its perimeter, and adjustable support feet are provided at the bottom. All moving parts cables (12) are stored inside the drag chain (10), and the vision component (1) is fixedly assembled by mounting bracket (101).

4. The intelligent ton bag loading and unloading robot as described in claim 1, characterized in that, The X-axis translation component (3) and Y-axis translation component (5) are equipped with drag chains (10) on both sides. The power cables (12) and signal cables (12) of the three-axis motion are all housed inside the drag chains (10). The top plate (26) is provided with a cable groove (18) to neatly fix the connecting cables (12) between the electronic control components.

5. The intelligent ton bag loading and unloading robot as described in claim 1, characterized in that, The electrical control integrated components adopt a layered power supply architecture: the switching power supply (13) supplies power to the vision component (1) and the camera controller (11); the 48-volt DC contactor (14) supplies power to the X-axis, Y-axis, Z-axis servo drive control parts and the clamping power motor (251); the step-down power supply (19) provides low-voltage signal power to the main control Huichuan (21) and the weighing transmitter (20), and all power lines are uniformly stored in the cable tray (18) and connected to the terminal block (22).

6. The intelligent ton bag loading and unloading robot as described in claim 1, characterized in that, The tension sensor (8) is an I-shaped four-hole mounting structure. The upper end is connected to the sliding body (23) of the Z-axis downward moving component (9) and the lower end is connected to the load-bearing hook component (2). The lifting load can be transmitted through the tension sensor (8) throughout the process. The weighing transmitter (20) can collect the load signal of the tension sensor (8) in real time and transmit it to the main control unit (21).

7. The intelligent ton bag loading and unloading robot as described in claim 1, characterized in that, The vision component (1) is equipped with a laser rangefinder to detect the vertical height between the machine and the ton bag. After the height reaches the standard, the vision component (1) can identify the plane coordinates of the lifting rope. The X-axis translation component (3) and the Y-axis translation component (5) drive the Z-axis downward component (9) to move above the lifting rope. The Z-axis downward component (9) pushes the electromagnet (7) to adhere to the metal patch of the lifting rope to complete the adsorption and gripping. The forklift interface (4) is a standardized quick-installation structure that can be adapted to the front-end mounting of different models of forklifts. The translation stroke of the X-axis translation component (3) and the Y-axis translation component (5) can cover the spacing of the lifting rope of various specifications of ton bags. The three-axis linkage adjustment can adapt to the operation of ton bags of different length and width dimensions.

8. The intelligent ton bag loading and unloading robot as described in claim 4, characterized in that, The main control unit (21) is interconnected with the vision component (1), the tension sensor (8), the electromagnet (7), the X-axis servo drive control unit (15), the Y-axis servo drive control unit (16), the Z-axis servo drive control unit (17), and the clamping power motor (251). After the tension sensor (8) detects the effective lifting load, the main control unit (21) can control the clamping power motor (251) to close the load-bearing hook component (2). After the load-bearing hook locking limit component (6) completes the locking, the main control unit (21) cuts off the power supply to the electromagnet (7) and can mechanically bear the weight of the ton bag by relying on the load-bearing hook component (2).

9. A method for automatically loading and unloading ton bags based on the intelligent ton bag loading and unloading robot according to any one of claims 1-8, characterized in that, Includes the following steps: S1. Equipment mounting: The intelligent ton bag loading and unloading robot is fixed to the front end of the forklift via the forklift interface (4), and the forklift drives the whole machine to move above the ton bag to be transferred; S2. Height measurement and positioning: The laser rangefinder mounted on the vision component (1) detects the vertical height of the whole machine and the ton bag in real time, and the forklift finely adjusts the machine height to the effective range identified by the vision component (1); S3. Lifting rope visual recognition: The vision component (1) collects the image of the ton bag lifting rope, the main control Huichuan (21) calculates the plane coordinates of the lifting rope, and sends displacement commands to the X-axis servo drive control part (15) and the Y-axis servo drive control part (16); S4. Three-axis alignment magnetic attraction: The X-axis translation component (3) and the Y-axis translation component (5) work together to move the Z-axis downward component (9) to the top of the target lifting rope, and the Z-axis downward component (9) pushes the electromagnet (7) downward. The electromagnet (7) is energized and attracts the metal patch on the lifting rope to complete the pre-grabbing of the lifting rope; S5. Three-axis return to zero: X Y-axis translation component (3), Y-axis translation component (5), Z-axis translation component (5) The shaft lowering component (9) is synchronously reset to the original position of the equipment; S6, load detection and mechanical locking hook: the forklift lifts the whole machine, the tension sensor (8) collects the lifting tension in real time, and after detecting the effective ton bag load, the main control Huichuan (21) starts the clamping power motor (251), the clamping power motor (251) drives the gear through the active wheel (252) and passive wheel (254) to further drive the first part (255) and the second part (256) of the load-bearing hook to close, the locking groove (62) of the locking block (61) fits the coaxial locking block (257) to achieve locking, and completes the mechanical self-locking. Then the main control Huichuan (21) cuts off the power supply of the electromagnet (7); S7, transfer and unloading: the forklift lifts the whole machine to the safe transfer height and travels to the target unloading position. The main control Huichuan (21) controls the clamping power motor (251) to run in reverse, driving the load-bearing hook component (2) to open and release the ton bag lifting rope, and complete the single automatic loading and unloading operation of the ton bag.

10. The automatic loading and unloading method for ton bags using the intelligent ton bag loading and unloading robot as described in claim 9, characterized in that, The camera controller is a camera industrial computer, model: SHIpcW631SA24207457; The power switch is a 48V DC~24V DC 200W switching power supply; The DC contactor is a 48V DC contactor; The main controller is Huichuan PLCEASY521; Vision component model: CBLETH5MLU; Tension sensor model: ZMX0420SAA.

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