A method and device for generating control parameters of a palletizing grouping station

Abstract

The application relates to the technical field of automatic packaging production line control, and provides a device control parameter generation method and device applied to a stacking grouping station, which comprises the following steps: obtaining description information of a target arrangement mode; and based on the description information, automatically generating a device control parameter set and a control action sequence through a parameter generation model. The application realizes automatic generation and one-key switching of device control parameters, reduces operation difficulty, shortens debugging time, improves model changing efficiency and production stability, and meets the demand of co-line flexible production of multi-variety and multi-specification products.

Description

Technical Field

[0001] This application belongs to the field of automated packaging production line control technology, specifically relating to a method and apparatus for generating equipment control parameters for palletizing and grouping stations. Background Technology

[0002] Currently, in automated production lines in industries such as beverages, food, and pharmaceuticals, palletizers are key equipment for realizing the transfer of products from the production line to warehousing and logistics. The grouping station, as the core pre-processor of the palletizer, is responsible for arranging single-box products into standard stacks according to preset rules, and then conveying them to the palletizer to complete the stacking operation.

[0003] In existing technologies, the control of stacking patterns in grouping stations generally adopts a manual programming and debugging method. For different product specifications and stacking pattern requirements, technicians need to manually configure a large number of formula parameters and write or modify corresponding control programs for each new stacking pattern. This manual programming and debugging method has many drawbacks: low changeover efficiency, requiring machine shutdown and debugging each time a stacking pattern is switched, and time-consuming parameter configuration and program modification, severely impacting the overall efficiency of the production line equipment; high operational threshold, relying on professional technicians for programming and parameter configuration, which ordinary operators cannot complete independently; prone to errors and poor stability, manual configuration of a large number of parameters is prone to input errors or logical conflicts, leading to non-standard stacking patterns and even equipment jams, product damage, and other malfunctions; weak flexibility and adaptability, unable to quickly adapt to new product specifications and new stacking patterns, making it difficult to meet the flexible production needs of multiple varieties and small batches; high maintenance costs, with different stacking patterns corresponding to different program versions, complex program management, and significant difficulties in subsequent maintenance and upgrades.

[0004] Therefore, there is an urgent need for a method and apparatus for generating equipment control parameters for palletizing and grouping stations to improve related technologies. Summary of the Invention

[0005] In view of the shortcomings of the prior art, the purpose of this application is to provide a method and apparatus for generating equipment control parameters for palletizing and grouping stations.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A method for generating equipment control parameters for a palletizing and grouping station, the method comprising: Obtain descriptive information about the target arrangement pattern; Based on the described information, a set of device control parameters and a sequence of control actions are automatically generated through a parameter generation model.

[0007] In one implementation, the parameter generation model includes a parameter calculation module and an action sequence arrangement module; The parameter calculation module is used to calculate the device control parameter set based on the description information; The action sequence arrangement module is used to arrange control action sequences according to the description information.

[0008] In one implementation, the action sequence orchestration module is configured with multiple action groups, each of which can be enabled or disabled independently; Each action group independently arranges multiple action units, and each action unit uses the position signal detected by the encoder as the start condition; at least some of the action units have overlapping execution periods, and the transfer of control authority between action units with overlapping execution periods is achieved through state transmission. After completing its own task, the current action unit releases control over the steering mechanism and triggers the next action unit to acquire the control authority.

[0009] In one implementation, each action unit includes a parameter parsing layer and an action execution layer; The parameter parsing layer parses the action unit into a corresponding action mode based on the action type and product conveying direction; the action modes include disabled mode, straight-through mode, turning mode, interval baffle mode and spacing control mode; Specifically, when the action type is a disabled type, it is parsed as the disabled mode; when the action type is a forward type and the product conveying direction is consistent with the product orientation required by the action type, it is parsed as the straight-through mode; when the action type is a forward type and the product conveying direction is inconsistent with the product orientation required by the action type, it is parsed as the turning mode; when the action type is a separation type, it is parsed as the interval baffle mode; and when the action type is a spacing control type, it is parsed as the spacing control mode.

[0010] As one implementation method, the execution logic of each action mode is as follows: The disabled mode: marks the current action unit as running, allows the next action unit to start and take over the control of the steering mechanism, and ends the current action unit; The straight-through mode: Start the conveyor belt, calculate the product's travel distance on the conveyor belt based on the encoder, reduce the conveyor belt speed when the travel distance reaches the deceleration distance set value, determine that feeding is complete when the travel distance reaches the box inlet displacement set value, stop the conveyor belt and allow the next action unit to start; The steering mode is as follows: the conveyor belt is started, the product travels on the conveyor belt based on the encoder, and when the travel distance reaches the set value of the box displacement, the steering cylinder is controlled to perform a steering action according to the preset configuration to adapt to products of different sizes. The current action unit ends after the product is detected to have passed the impact sensor. The interval baffle mode: the travel distance of the roller conveyor belt is calculated based on the encoder, and when the travel distance reaches the set target value, the interval baffle rise signal is output. The spacing control mode is as follows: the chain conveyor belt is stopped, and the next action unit is allowed to start after the roller conveyor belt has traveled a set distance.

[0011] As one implementation, the method further includes: After the last product in all action units passes the sensor upon impact, the distance traveled by the last box is calculated based on the encoder; the formula for calculating the distance L of the last box is:

[0012] in, This represents the current encoder pulse value. The starting encoder pulse value is D, where D is the drum diameter. The total number of pulses for one revolution of the encoder; when the last box travels a set distance, the entire sequence of control actions is completed.

[0013] In one implementation, the parameter calculation module calculates at least one of the following parameters based on the material size and arrangement quantity in the description information: conveying mechanism parameters, separating mechanism parameters, pushing mechanism parameters, pre-clamping mechanism parameters, and carrier configuration parameters. The conveying mechanism parameters include conveyor belt speed settings and steering cylinder configurations. The conveyor belt speed settings include high speed, medium speed, and low speed. The steering cylinder configurations include multiple configuration values, each corresponding to a different combination of cylinder actions to adapt to products of different sizes. The separation mechanism parameters include the separation plate position parameters, specifically the position of the separation plate n. The calculation formula is:

[0014] in, The reference distance from partition 1 to the impact completion sensor. For product packaging width, The spacing between the partitions, This is the encoder scaling factor; The parameters of the pushing mechanism include the parameters of the vertical push plate and the parameters of the horizontal pusher; The pre-clamping mechanism parameters include clamping position parameters and positioning mode parameters; the positioning mode parameters include positioning detection mode parameters and deceleration positioning mode parameters; the positioning detection mode parameters are used to configure the triggering conditions for the push-in operation; the deceleration positioning mode parameters are used to configure the motion control mode of the pre-clamping mechanism. The vehicle configuration parameters include position parameters and motion parameters of multiple servo drives; the position parameters include clamping position, opening position, and releasing position of each servo drive; the motion parameters include running speed parameters, acceleration parameters, and deceleration parameters; wherein, the position parameters of the rear positioning servo include limit position parameters; and the position parameters of the front positioning servo include trigger position parameters.

[0015] As one implementation, before sending the device control parameter set and the control action sequence to the device controller, the method further includes: Perform a validity check on the entire set of parameters; if the check fails, prevent the parameters from being issued, display an error message, and lock the device from starting. The legality verification includes at least one of the following: the parameter must not be negative, the position parameter must not exceed the mechanical travel range, the infeed displacement is greater than the deceleration distance, the partition plate number is within its corresponding valid range, the action type is its corresponding valid type, and the steering cylinder configuration is its corresponding valid configuration value.

[0016] The present invention also provides a device for generating device control parameters, including a processor and a memory, wherein the memory stores a computer program, and when the computer program is executed by the processor, it implements the steps of the method described in any of the above-described schemes.

[0017] The present invention also provides a computer-readable storage medium having a computer program stored thereon, wherein the computer program, when executed by a processor, implements the steps of the method described in any of the above embodiments.

[0018] Beneficial Effects: This invention, through a parameter generation model, automatically generates a set of equipment control parameters and a sequence of control actions based on the description information of the target arrangement pattern, thus achieving automatic generation of control logic and replacing the manual programming and debugging methods used in existing technologies. This automated process fundamentally lowers the operational threshold, allowing ordinary employees to complete the changeover without the need for specialized technical personnel. Parameters are automatically generated by the algorithm according to equipment rules, eliminating human input errors and ensuring standardized stacking and stable equipment operation. Unified parameter generation, distribution, and one-time activation avoid step-by-step debugging and verification, significantly shortening changeover time and solving the problems of cumbersome and inefficient debugging in existing technologies. The algorithm is compatible with different sizes, arrangements, and stacking structures, supporting multi-product co-production, addressing the pain point of traditional solutions' inability to quickly adapt to new products, and improving the flexibility of the production line. Attached Figure Description

[0019] The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this application. Throughout the drawings, the same reference numerals denote the same components. Obviously, the drawings described below are merely some embodiments described in this application, and those skilled in the art can obtain other drawings based on these drawings.

[0020] Figure 1 This is a flowchart illustrating a method for generating equipment control parameters for a palletizing grouping station, as provided in an embodiment of this application.

[0021] Figure 2 and Figure 3 This is a structural schematic diagram of a palletizing grouping station from different angles, provided as an embodiment of this application.

[0022] Figure 4 This is a schematic diagram showing the basic parameters page of a palletizing grouping station provided in an embodiment of this application.

[0023] Figure 5 This is a schematic diagram showing the general parameter page of a palletizing grouping station provided in an embodiment of this application.

[0024] Figure 6 This is a schematic diagram showing another general parameter page of a palletizing grouping station provided in an embodiment of this application.

[0025] Figure 7 This is a schematic diagram showing the parameter page of the separating mechanism of a palletizing grouping station provided in an embodiment of this application.

[0026] Figure 8 This is a schematic diagram of the display interface for the grouping operation configuration of a palletizing grouping station provided in an embodiment of this application.

[0027] Figure 9 This is a schematic diagram showing the parameters of the pre-clamping mechanism of a palletizing grouping station provided in an embodiment of this application.

[0028] Figure 10 This is a schematic diagram showing the display interface of the vehicle configuration parameter page of a palletizing grouping station provided in an embodiment of this application. Detailed Implementation

[0029] To enable those skilled in the art to better understand the technical solutions in the embodiments of this application, the technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. It should be understood that these descriptions are exemplary only and are not intended to limit the scope of this application. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this application. Furthermore, in the following description, descriptions of well-known structures and technologies are omitted to avoid unnecessarily obscuring the concepts disclosed in this application.

[0030] Example 1: like Figure 1 As shown, this embodiment provides a method for generating equipment control parameters for a palletizing grouping station. The method includes steps S100 and S200.

[0031] Step S100: Obtain the description information of the target arrangement pattern.

[0032] Specifically, the descriptive information of the target arrangement pattern refers to the basic data set used to define the final arrangement form of the materials. In this embodiment, the descriptive information includes material size, arrangement quantity, arrangement direction, number of palletizing layers, and product conveying direction. Material size refers to the length, width, and height of the material to be arranged (such as beverage boxes, packaging boxes, etc.), for example, a length of 395mm, a width of 198mm, and a height of 183mm. Arrangement quantity refers to the number of materials arranged horizontally and vertically in each layer, for example, 5 horizontal arrangements and 3 vertical arrangements. Arrangement direction refers to the orientation of the material during conveying, for example, the long side facing forward or the short side facing forward. Number of palletizing layers refers to the total number of stacked layers, for example, 5 layers. Product conveying direction is used by the subsequent action sequence orchestration module to automatically determine the action mode of the action unit, such as determining whether the material needs to be turned. It should be understood that the specific content of the descriptive information can be adjusted according to the actual application scenario. For example, in non-palletizing scenarios, the number of palletizing layers can be replaced with the stacking height or the number of stacked layers, as long as the target arrangement pattern can be defined. By acquiring this descriptive information, the system obtains all the input data needed to generate control parameters and action sequences, replacing the existing method of manually configuring dozens of complex parameters one by one, thus reducing the operational threshold from the source.

[0033] Step S200: Based on the description information, automatically generate a set of device control parameters and a sequence of control actions using a parameter generation model.

[0034] Specifically, the parameter generation model is an algorithmic model that incorporates stacking type analysis rules, equipment action models, and parameter correlation relationships. This model receives the descriptive information input in step S100, automatically derives and outputs a complete set of equipment control parameters and control action sequences. The equipment control parameter set refers to the set of numerical parameters required to drive the operation of each mechanism of the equipment, such as conveyor belt speed, partition plate position, pusher plate stroke, and pre-clamping position.

[0035] The control action sequence refers to the logical order and timing of the coordinated actions of various mechanisms within the equipment. For example, the conveying action is performed first, followed by the turning action, and finally the pushing action. In this embodiment, the parameter generation model can automatically generate a complete set of parameters and sequences based on the description information, eliminating the need for manual programming or item-by-item debugging. For instance, after inputting the material size and arrangement quantity, the model automatically calculates the position parameters of the partition plate and automatically arranges the action sequence of the turning mechanism. This automatic generation method achieves automated mapping from description information to control logic, significantly improving changeover efficiency, reducing manual configuration errors, and ensuring the standardization of stack arrangement and the stability of equipment operation.

[0036] It should be noted that this embodiment only describes the input and output of the model and does not involve the specific algorithm structure inside the model. The specific implementation of the model will be described in detail in subsequent embodiments.

[0037] As one implementation method, the production line speed parameters in the equipment control parameter set are only used to display the maximum value on the instrument panel and are not involved in the actual control calculation.

[0038] Specifically, the production line speed parameter (e.g., 36000 BPH) reflects the theoretical capacity of the production line. This parameter serves only as a reference value displayed on the instrument panel within the equipment control parameter set, used by operators to monitor the production line status. It does not directly participate in the calculation of actual control logic such as conveyor belt speed and pusher speed. Parameters required for actual control calculations (e.g., conveyor belt speed setting, infeed displacement distance, etc.) are automatically generated by the parameter generation model based on the descriptive information. This design avoids interference from the production line speed parameter to the control logic, improving the system's stability and adaptability.

[0039] Through the above solution, this embodiment realizes the automatic generation of equipment control parameters. Operators only need to input a small amount of basic descriptive information, and the system can automatically generate a complete set of control parameters and action sequences. This replaces the existing technology that relies on professional technicians to manually program and debug, significantly reducing the difficulty of operation, shortening the changeover time, and improving production efficiency and system stability.

[0040] Example 2: This embodiment, based on embodiment 1, provides a detailed description of the specific architecture of the parameter generation model and the arrangement mechanism of the control action sequence.

[0041] The parameter generation model comprises a parameter calculation module and an action sequence arrangement module. The parameter calculation module calculates the set of equipment control parameters based on the descriptive information, while the action sequence arrangement module arranges the sequence of control actions based on the descriptive information. Specifically, the parameter calculation module handles static parameters of numerical value, such as calculating the position of the partition plate and the stroke of the pusher plate based on material dimensions; its output is directly used as the setpoint for equipment operation. The action sequence arrangement module handles dynamic parameters of logical value, i.e., determining the sequence of actions, triggering conditions, and interlocking relationships of each mechanism.

[0042] This modular design decouples parameter calculation from logic orchestration, so that when the stack arrangement logic needs to be adjusted, only the configuration of the action sequence orchestration module needs to be modified, without recalculating the basic parameters, and vice versa, thereby improving the system's maintenance efficiency and flexibility.

[0043] Furthermore, the action sequence arrangement module is configured with multiple action groups, each of which can be enabled or disabled independently; each action group independently arranges multiple action units, and each action unit uses the position signal detected by the encoder as the start condition; at least some of the action units have overlapping execution periods, and the transfer of control authority between action units with overlapping execution periods is achieved through state transmission. After completing its own task, the current action unit releases control over the steering mechanism and triggers the next action unit to acquire the control authority.

[0044] An action group can be understood as a logical set for a specific material pushing task or a specific product flow. For example, the pushing action for a certain layer of products can be configured as an action group. When the products in that layer do not need to be pushed in, the entire action group can be directly turned off by an enable switch without deleting or modifying the internal action units, making the operation convenient. Each action group independently arranges multiple action units. The action unit is the smallest execution unit of the control logic, such as "long side forward" or "partition rise".

[0045] In this embodiment, the action units operate in parallel and interleaved manner. Specifically, the execution of an action unit is not a simple sequential waiting process, where the next action unit only starts after the previous one has completely finished. Instead, it determines when to start the next action unit, when to request and release control of the steering mechanism, and when to allow the next action unit to control the steering mechanism based on its own task. For example, after action unit A completes the feeding detection, it can start action unit B, while action unit A continues to execute subsequent steering request logic. The two overlap in time, thereby shortening the overall cycle time. This parallel and interleaved mechanism maximizes the operating efficiency of the equipment through fine-grained resource scheduling.

[0046] The triggering of the action unit is based on encoder position rather than time sequence. Specifically, the encoder collects the displacement pulses of the conveyor belt in real time, and the action triggering condition is set to "execute when the encoder pulse value reaches a preset threshold". For example, the triggering condition for the partition plate to rise is "the roller conveyor belt travels a distance of 500mm". The travel distance corresponding to the encoder pulse is calculated in real time, and the action is triggered immediately once the threshold is reached. Compared with traditional time-series-based triggering (such as "rise after a 2-second delay"), encoder position-based triggering is not affected by conveyor belt speed fluctuations. When the conveyor belt speed becomes unstable due to load changes, time-based triggering will cause the actual triggering position to shift, while encoder triggering always ensures that the action is executed at a precise physical position, thereby significantly improving positioning accuracy and the reliability of action connection.

[0047] Furthermore, each action unit includes a parameter parsing layer and an action execution layer; The parameter parsing layer parses the action unit into a corresponding action mode based on the action type and product conveying direction; the action modes include disabled mode, straight-through mode, turning mode, interval baffle mode and spacing control mode; Specifically, when the action type is a disabled type, it is parsed as the disabled mode; when the action type is a forward type and the product conveying direction is consistent with the product orientation required by the action type, it is parsed as the straight-through mode; when the action type is a forward type and the product conveying direction is inconsistent with the product orientation required by the action type, it is parsed as the turning mode; when the action type is a separation type, it is parsed as the interval baffle mode; and when the action type is a spacing control type, it is parsed as the spacing control mode.

[0048] The aforementioned parameter parsing layer automatically parses the action unit into a defined action mode based on the action type and product conveying direction. Specifically, the operator selects the action type (e.g., "long side forward" or "short side forward") and inputs the product conveying direction (e.g., "long side forward" or "short side forward") in the configuration interface. The upper parsing layer then makes a determination based on preset logical rules. When the product conveying direction matches the required direction of the action, it is automatically parsed as a straight-through mode; when the directions do not match, it is automatically parsed as a turning mode. This two-layer architecture separates logical determination from physical execution. The upper layer is responsible for translating the configuration intent, while the lower layer is responsible for executing specific instructions, reducing configuration complexity and avoiding human error.

[0049] The action modes include disabled mode, straight-through mode, steering mode, gap barrier mode, and spacing control mode. The execution logic of each action mode is explained in detail below.

[0050] The disabled mode: marks the current action unit as running, allows the next action unit to start and take over control of the steering mechanism, and terminates the current action unit. This mode is typically used to skip certain unnecessary action steps, equivalent to a logical "straight-through," but without any physical action.

[0051] The direct-flow mode involves starting the conveyor belt, calculating the product's travel distance on the belt based on the encoder, reducing the conveyor belt speed when the travel distance reaches the deceleration distance set value, and determining that feeding is complete when the travel distance reaches the infeed displacement set value. The conveyor belt then stops, allowing the next action unit to start. Specifically, this mode is suitable for scenarios where the product orientation already meets requirements and no turning is needed. By detecting the product's arrival at the feed sensor and then accurately calculating the displacement using the encoder, the conveyor belt speed is controlled in stages to ensure the product smoothly enters the next workstation, reducing impact.

[0052] The steering mode involves: starting the conveyor belt, calculating the product's travel distance on the conveyor belt based on the encoder, and controlling the steering cylinder to perform a steering action according to a preset configuration to adapt to products of different sizes when the travel distance reaches the set value for the infeed displacement. The current action unit ends after detecting that the product has passed the impact completion sensor. Specifically, this mode is suitable for scenarios where the product needs to change direction. Before the product enters the steering station, the cylinder combination is automatically selected based on the product size (e.g., only cylinder 1 operates, or cylinders 1 and 2 operate simultaneously) to adjust the angle of the steering baffle. The product, driven by the conveyor belt, impacts the baffle to complete the steering, and the steering completion is confirmed by the impact completion sensor. This mode achieves adaptive steering for products of different sizes through the flexible configuration of the cylinder combination.

[0053] The interval baffle mode: Based on the encoder, the travel distance of the roller conveyor belt is calculated. When the travel distance reaches the set target value, a baffle raising signal is output. This mode can be used for product grouping. By raising and lowering the baffles, physical intervals are formed in the product queue, providing accurate grouping boundaries for subsequent pushing actions.

[0054] The spacing control mode stops the chain conveyor belt and allows the next action unit to start after the roller conveyor belt has traveled a set distance. This mode can be used to adjust the spacing between products by coordinating the movement of the chain conveyor belt and the roller conveyor belt to increase the product spacing and prevent interference from subsequent actions.

[0055] Furthermore, the method also includes: After the last product in all action units passes the sensor upon impact, the distance traveled by the last box is calculated based on the encoder; the formula for calculating the distance L of the last box is:

[0056] in, This represents the current encoder pulse value. The starting encoder pulse value is D, where D is the drum diameter. The total number of pulses for one revolution of the encoder; when the last box travels a set distance, the entire sequence of control actions is completed.

[0057] Specifically, when the last product passes the sensor by impact, the system records the encoder pulse value at that moment as... The roller conveyor belt then continues to run, calculating the travel distance L in real time. When L reaches the set value, it means that the group of products has completely reached the push-in station, the entire control sequence is complete, and the push-in action is triggered. This calculation method accurately determines the end of the sequence through physical displacement, avoiding the uncertainty of time estimation and ensuring the integrity of the stack arrangement.

[0058] Example 3: This embodiment, based on embodiment 1, provides a detailed explanation of the specific calculation logic of the parameter calculation module.

[0059] The parameter calculation module calculates at least one of the following parameters based on the material size and arrangement quantity in the description information: conveying mechanism parameters, separating mechanism parameters, pushing mechanism parameters, pre-clamping mechanism parameters, and carrier configuration parameters. The conveying mechanism parameters include conveyor belt speed settings and steering cylinder configurations. The conveyor belt speed settings include high speed, medium speed, and low speed. The steering cylinder configurations include multiple configuration values, each corresponding to a different combination of cylinder actions to adapt to products of different sizes. The separation mechanism parameters include the separation plate position parameters, specifically the position of the separation plate n. The calculation formula is:

[0060] in, The reference distance from partition 1 to the impact completion sensor. For product packaging width, The spacing between the partitions, This is the encoder scaling factor; The parameters of the pushing mechanism include the parameters of the vertical push plate and the parameters of the horizontal pusher; The pre-clamping mechanism parameters include clamping position parameters and positioning mode parameters; the positioning mode parameters include positioning detection mode parameters and deceleration positioning mode parameters; the positioning detection mode parameters are used to configure the triggering conditions for the push-in operation; the deceleration positioning mode parameters are used to configure the motion control mode of the pre-clamping mechanism. The vehicle configuration parameters include position parameters and motion parameters of multiple servo drives; the position parameters include clamping position, opening position, and releasing position of each servo drive; the motion parameters include running speed parameters, acceleration parameters, and deceleration parameters; wherein, the position parameters of the rear positioning servo include limit position parameters; and the position parameters of the front positioning servo include trigger position parameters.

[0061] Specifically, the parameter calculation module incorporates kinematic models and geometric constraints for various mechanisms. Once the material dimensions (e.g., 395mm long, 198mm wide, and 183mm high) and arrangement quantity (e.g., 5 horizontally and 3 vertically) are obtained, the module automatically calls the corresponding calculation formula to generate the precise values ​​required to drive the servo motors, cylinders, and conveyor belts of each mechanism. This automated calculation mechanism replaces the traditional method of manually adjusting parameters based on experience through repeated trial and error, ensuring the accuracy and consistency of parameter generation and significantly reducing the configuration error rate.

[0062] The core of the separation mechanism parameters lies in the accurate calculation of the separation plate position parameters. The formula for calculating the position of separation plate n is: Where D1 is the reference distance from partition 1 to the impact completion sensor, which serves as the physical origin for positioning all partitions; for example, it can be set to 50mm. W is the product packaging width, directly taken from the material width data in the description information. S is the partition spacing, referring to the standard mechanical spacing between adjacent partitions, for example, 40mm. K is the encoder proportional coefficient, calculated as K = encoder resolution ÷ roller circumference, used to convert physical distance into pulse values ​​recognizable by the controller. Using this formula, the system can calculate the trigger positions of all partitions at once. For example, when the number of groups is 7, it automatically calculates the positions of partitions 1 to 7 and automatically fills them into the configuration interface.

[0063] Furthermore, the total number of separators is automatically set by the algorithm based on the number of groups, and unused separator settings are automatically hidden. For example, if the current stack type only requires 3 separators, the configuration items for separators 4 to 16 on the interface will be automatically grayed out or hidden, preventing operators from accidentally activating inactive separators. Separators also have correction values ​​to increase or decrease the actual distance between separators. This correction value allows operators to fine-tune the automatically calculated positions based on actual on-site operating conditions (such as product packaging tolerances and conveyor belt wear), enhancing the system's adaptability. The algorithm automatically maps separator numbers to hardware output channels through separator index parameters. Specifically, the algorithm internally establishes a mapping table between separator logical numbers (such as Spacer_1) and physical hardware output module channels (such as output channel 8 of module 1). After calculation, control commands are directly sent to the corresponding hardware channels without the need for manual wiring diagram lookup and binding, achieving seamless "calculation as configuration" integration.

[0064] In summary, through the automatic calculation and intelligent matching of the above-mentioned parameters, this embodiment achieves a precise mapping from basic material data to a complete set of equipment control parameters. This not only significantly improves the efficiency of parameter configuration, but also fundamentally eliminates common numerical errors, logical conflicts, and hardware mapping mistakes in manual configuration through formulaic calculation and logical verification, thereby significantly improving the stability and safety of equipment operation.

[0065] Example 4: This embodiment, based on embodiments 1 to 3, provides a detailed explanation of the verification mechanism and distribution process before parameter distribution.

[0066] Before sending the device control parameter set and the control action sequence to the device controller, the method further includes: Perform a validity check on the entire set of parameters; if the check fails, prevent the parameters from being issued, display an error message, and lock the device from starting. The legality verification includes at least one of the following: the parameter must not be negative, the position parameter must not exceed the mechanical travel range, the infeed displacement is greater than the deceleration distance, the partition plate number is within its corresponding valid range, the action type is its corresponding valid type, and the steering cylinder configuration is its corresponding valid configuration value.

[0067] Specifically, the validity check occurs between the completion of parameter calculation and its execution. Although the parameters automatically generated by the parameter generation model have undergone algorithmic logic derivation, they may still result in invalid parameters due to abnormal input description information (such as negative material size input) or improper handling of algorithm boundary conditions. If these invalid parameters are directly sent to the equipment controller, it may lead to abnormal equipment operation, mechanical collisions, or even safety accidents.

[0068] Therefore, after generating a complete set of parameters, the model automatically iterates through all parameter items and verifies them according to preset physical and logical rules. If any parameter is found to be non-compliant, the distribution process is immediately terminated, the erroneous parameter item is highlighted on the human-machine interface, and an error message (such as "Separator position exceeds travel range") is output. Simultaneously, the device's start button is locked, forcing the operator to correct the error. This pre-verification mechanism intercepts potential safety hazards before execution, fundamentally preventing illegal parameters from entering the control process and significantly improving security and stability.

[0069] The legality verification includes at least one of the following: the parameter must not be negative, the position parameter must not exceed the mechanical travel range, the infeed displacement is greater than the deceleration distance, the partition plate number is within its corresponding valid range, the action type is its corresponding valid type, and the steering cylinder configuration is its corresponding valid configuration value.

[0070] Specifically, each verification rule corresponds to a specific physical or logical constraint. Parameters cannot be negative, meaning all parameters such as size, position, and speed must be positive. This is a fundamental property of the physical world; negative values ​​indicate calculation errors or abnormal input data. Position parameters must not exceed the mechanical travel range, meaning servo positioning parameters such as push plate travel and clamping position must be within the limits allowed by the mechanical structure. For example, if the maximum travel of a push plate is 1000mm, and the calculated push-in target position is 1100mm, it is considered illegal to prevent the push plate from hitting the mechanical limit and damaging the equipment. The feed box displacement must be greater than the deceleration distance, meaning the deceleration point during the conveyor belt feeding process must be before the stopping point. If the deceleration distance is greater than the feed box displacement, it means the conveyor belt has decelerated before reaching the stopping point, which will lead to logical conflicts and chaotic actions, affecting feeding accuracy. The separator plate number must be within a valid range, meaning the separator plate index number calculated by the algorithm must be within the range of the actual number of separator plates installed in the hardware. For example, if the system only has 7 separator plates installed, and the calculation result triggers the 8th separator plate, it is considered illegal. The action type must be valid, meaning the action type generated by the action sequence orchestration module must exist in the preset action library to prevent undefined action commands. The steering cylinder configuration must be a valid value, meaning the combination of steering cylinders must be within the preset configuration table. For example, only combinations of "Cylinder 1," "Cylinder 2," and "Cylinder 1+2" are allowed. If an illegal configuration such as "Cylinder 3" appears, it is considered an error. Through these multi-dimensional verification rules, the system ensures the physical rationality and logical consistency of the issued parameters.

[0071] The set of equipment control parameters and the sequence of control actions are packaged as recipe data and sent to the equipment controller at once. The recipe data includes at least one of the following: recipe number, material size, number of arrangements, number of palletizing layers, and robot program number. Specifically, after the validity check is passed, the parameter generation model encapsulates all previously calculated equipment control parameters (such as conveyor belt speed, partition plate position, pusher travel, etc.) and the arranged sequence of control actions (such as the sequence logic of Action1 to Action14) into a complete recipe data package. This recipe data package not only contains the parameters and logic required for control, but also descriptive information such as recipe number, material size, number of arrangements, number of palletizing layers, and robot program number, which are used to identify the specific product and pallet type corresponding to the recipe. The operator selects the target recipe (such as "Demo Product") in the recipe management interface and clicks the "Load" or "Configure" button. The system then sends the entire recipe data package to the equipment controller, such as the PLC, at once through the communication interface. After receiving the data package, the controller automatically parses and updates the parameter settings and logic programs of each module, without the need for manual input or modification. This "one-click deployment" method replaces the tedious process of manual item-by-item verification, input, and debugging in traditional technologies, reducing changeover time from hours to minutes and achieving true "one-click switching," greatly improving production efficiency and ease of operation. At the same time, the unified packaging and management of formula data facilitates subsequent formula storage, retrieval, and version traceability, enhancing the digitalization level of production management.

[0072] Example 5: This embodiment applies the equipment control parameter generation method provided in the foregoing embodiments to a specific palletizing and grouping station production line scenario to demonstrate its changeover process and application effect in actual production.

[0073] See Figure 2 and Figure 3This is a structural diagram of the palletizing and grouping station from different angles. Along the product conveying direction, the palletizing and grouping station is arranged with a chain conveyor belt 105, a roller conveyor belt 104, a pre-clamping mechanism 101, and a grouping station pusher 103. The turning mechanism 102 (also called an impact mechanism) is located at the junction of the chain conveyor belt 105 and the roller conveyor belt 104. An infeed sensor 107 is located at the upstream end of the chain conveyor belt 105 to detect product arrival and trigger the encoder to record the starting position. A counting sensor 108 is located near the turning mechanism 102 along the conveying direction for product counting. The turning mechanism 102 is equipped with two turning cylinders to change the product orientation when executing the turning mode. An impact completion sensor 106 is located on its downstream side to detect product turning completion and trigger the next action unit to acquire control of the turning mechanism. The roller conveyor belt 104 is used to transport the product to the pre-clamping area. The pre-clamping mechanism 101 consists of pre-forming push rods set on the left and right sides of the pre-clamping area, which are used to automatically adjust and clamp the products according to the width of the stack. After the pre-clamping and positioning is completed, the pusher 103 pushes the arranged product group horizontally into the downstream carrier to complete the grouping action sequence.

[0074] As an example, in the palletizing and grouping station described above, which can be applied to a beverage production line, it is necessary to switch to producing a new product. The packaging dimensions of this product are 395mm long, 198mm wide, and 183mm high. The target arrangement is 5 boxes arranged horizontally and 3 boxes arranged vertically per layer, for a total of 5 layers, with the product conveying direction being forward along the long side. In traditional technology, for such changeover tasks, technicians need to stop the machine and manually configure dozens of parameters, such as conveyor belt speed, separator position, pusher stroke, pre-clamping position, and carrier servo parameters. They also need to write or modify the control logic program for actions such as turning, grouping, and pushing. The entire changeover and debugging process usually takes 30 to 60 minutes and is highly susceptible to equipment failure due to human input errors.

[0075] After applying the method provided by this invention, the model changeover process is as follows: Step S501: The operator inputs a description of the target arrangement pattern through the human-machine interface.

[0076] Specifically, operators only need to input a small amount of basic data in the main parameter configuration interface. See also Figure 4On the "Basic Parameters" page, the operator enters the product name, length 395mm, width 198mm, height 183mm in the packaging size field, horizontal quantity 5, vertical quantity 3 in the packaging specifications field, and palletizing layer number 5, etc. Among these, the following parameters are used: Number: Recipe number, which is fixed and cannot be modified. Name: Recipe name, maximum 40 characters, supports alphanumeric and symbols. Last save time: This parameter is automatically updated after each recipe save. Packaging size refers to the product dimensions. Packaging specifications: This parameter is used to calculate the current output. Stack size refers to the dimensions of one layer of product after forming. Number of boxes per layer: This refers to the number of boxes per layer, used to calculate the current output. Number of palletizing layers: This parameter controls the number of palletizing layers and is also used to calculate the current output. Robot program number: This is the robot program number used for calling the robot and corresponds to the robot program. Production line speed: This parameter is only used to display the maximum value on the dashboard.

[0077] See Figure 5The system automatically matches the product conveying direction to "long side forward" based on product size, and also matches the roller / panel conveyor belt speed, infeed displacement distance, deceleration distance, and turning distance. Production line speed parameters (e.g., 36000 BPH) are only used as a reference for dashboard display and are not involved in control calculations. These input data constitute the descriptive information of the target arrangement mode. After obtaining this information, a formula number is automatically generated and the storage time is recorded. Specifically, the product conveying direction—whether the product is produced with the long side forward (LSL) or the short side forward (SSL)—is determined by the on-site conveyor belt. The turning mechanism—cylinder extension—allows selection of the cylinder extension length based on actual needs. There are three length options, basically meeting daily production requirements. Roller conveyor belt speed selection: three speed levels: speed 0—high speed, speed 1—medium speed, speed 2—low speed. High speed is used when production capacity barely meets demand, medium speed when there is a small margin, and low speed when production capacity is fully met. Panel conveyor belt speed selection: three speed levels: speed 0—high speed, speed 1—medium speed, speed 2—low speed. High speed is used when production capacity barely meets demand, medium speed when there is a small margin in production capacity, and low speed when production capacity is fully met. Roller conveyor belt box entry spacing – Turning box: If the box (i.e., the product) needs to be turned, the panel conveyor belt will stop after it enters the roller conveyor belt until it has traveled the set distance at the rollers, after which the panel conveyor belt will restart. Increasing this value can increase system stability if the box turns more, but it will reduce the operating speed. Roller conveyor belt spacing mode – Distance setting: When the spacing mode is executed, the panel conveyor belt stops and waits for the rollers to travel a certain distance. This function is mainly used in conjunction with spacers. When the distance between two boxes running on the roller conveyor belt is too small, it means that the time left for the spacer to rise is also very short. This may cause the spacer to rise too slowly, resulting in misalignment of the entire stack. This function can increase the spacing between the two boxes, thereby improving system stability. Chain conveyor belt box entry displacement distance: This refers to how far the panel conveyor belt has traveled after the box encounters the infeed sensor before it is considered that the box has fully entered the roller conveyor belt. Empirical values: For long-side feeding, this value is approximately 65%-85% of the product width; for short-side feeding, it's approximately 65%-85% of the product width. Chain conveyor belt deceleration distance: This is used in conjunction with the parameter above (chain conveyor belt in-box displacement distance), referring to how far the box needs to travel before the panel conveyor belt decelerates. Its maximum value should not exceed the "chain conveyor belt in-box displacement distance" to avoid program errors. A higher value results in more stable box feeding, but the feeding speed will be slightly slower. Empirical values: This value is, for example, 60%-75% of the "chain conveyor belt in-box displacement distance".

[0078] Step S502: The parameter generation model automatically calculates the set of equipment control parameters.

[0079] The built-in parameter calculation module automatically calls the calculation formulas for various mechanisms based on the input description information to generate a complete set of equipment control parameters. For example, see... Figure 6 and Figure 7 For the parameters of the separating mechanism, according to the formula The system automatically calculates the precise positions of partitions 1 to 7 and automatically hides the configuration items of unused partitions 8 to 16. For the pushing mechanism parameters, it automatically calculates the return position of the vertical pusher to 283mm (product height + 100mm safety margin) based on the product height of 183mm, and automatically calculates the target pushing position of the horizontal pusher based on the stack width. For the pre-clamping mechanism parameters, it automatically matches the left and right clamping positions based on the stack width and defaults to enabling the positioning detection mode to ensure product alignment before pushing. For the conveyor mechanism parameters, it automatically recommends the medium speed setting for the conveyor belt based on production capacity requirements and automatically matches the steering cylinder configuration to a "cylinder 1+2" combination to adapt to the steering of large-sized products. All parameters are automatically generated by the algorithm and entered into the configuration interface; operators do not need to manually calculate or input any values.

[0080] Step S503: The action sequence arrangement module automatically arranges the control action sequence.

[0081] See Figure 8 The action sequence orchestration module automatically orchestrates the logic of multiple action groups based on the arrangement pattern and product conveying direction in the description information. In the grouping operation configuration interface, action sequences from Action1 to Action14 are automatically generated. For example, for the arrangement requirements of this product, Action1 is automatically orchestrated as "Spacing plate 3 rises," Action2 as "Short side forward" (because the product enters with its long side facing forward but requires arrangement along the short side, it is automatically parsed as a turning mode), Action3 as "Short side forward," Action4 as "Spacing mode," and Action5 as "Long side forward" (the direction is consistent, so it is automatically parsed as a straight-through mode). The remaining Actions are automatically set to disabled mode. Each action unit's action mode is automatically determined by the upper parsing layer and triggered by the lower execution layer based on the encoder position. The module also automatically calculates the last box's travel distance as 320mm to ensure accurate sequence end determination. The entire orchestration process requires no manual writing of logic code, automatically constructing complex action logic.

[0082] Step S504: Perform a validity check on the parameter generation model.

[0083] Before parameters are issued, the system automatically performs a validity check on the generated set of parameters and action sequences. It iterates through and checks each parameter: confirming that all dimensional and positional parameters are positive; confirming that the push-in target position does not exceed the mechanical travel limit; confirming that the infeed displacement distance is greater than the deceleration distance; confirming that the partition plate numbers are all within the valid range; and confirming that the steering cylinder configuration is a valid value. If the check passes, the issuance process is allowed; if an error is found (such as a positional parameter exceeding the limit), the error is immediately displayed on the interface, the equipment is locked, and the operator is forced to correct it.

[0084] Step S505: Send the formula data to the equipment controller with one click.

[0085] After successful verification, the formula data, including equipment control parameter sets, control action sequences, formula numbers, and material dimensions, is packaged together. The operator clicks the "Load" button on the formula management interface to send the entire formula data package to the PLC controller via the communication interface. Upon receiving the data, the PLC automatically updates the parameter settings and logic programs of each module, and the conveying, steering, grouping, pushing, pre-clamping, and carrier mechanisms immediately begin to operate in sync according to the new parameters and logic. See also... Figure 9 and Figure 10 These are the display interfaces for the pre-clamping mechanism parameters and the vehicle configuration parameters, respectively.

[0086] Through the above process, operators only need to input a small amount of descriptive information on the interface and click a few buttons to complete the entire changeover process within 1 to 3 minutes. No professional technicians are required, no machine downtime is needed for debugging, and parameters are error-free. After the equipment starts, the products sequentially pass through conveying, turning, grouping, pre-clamping, pushing, and carrier grabbing stages, precisely arranging them into the target stack shape. Compared to the traditional manual changeover process which takes 30 to 60 minutes, this invention improves changeover efficiency by over 90%, significantly enhancing the overall equipment efficiency and flexible production capacity of the production line.

[0087] Example 6: To further verify the technical advantages of the action unit triggering mechanism in this invention, this embodiment constructs a comparative scenario to compare and analyze the encoder position-based triggering method adopted in this invention with the time-series-based triggering method commonly used in the prior art.

[0088] Specifically, on the same palletizing and grouping production line, the mechanical structure of the conveyor belt, product size, and arrangement pattern are kept completely consistent; only the triggering logic of the action unit is changed. The scenario is as follows: During operation, the conveyor belt experiences speed fluctuations due to load changes (such as uneven feeding), with the speed fluctuating by approximately 10% around the standard value. The task of the action unit is to control the spacer to accurately rise when the product has traveled 500mm after impacting the sensor.

[0089] When using the existing time-based triggering method, the control system calculates a delay of 0.5 seconds for the spacer to rise based on the standard speed of the conveyor belt (e.g., 1 m / s). However, due to fluctuations in the actual conveyor belt speed, when the actual speed is lower than the standard speed (e.g., 0.9 m / s), the product only travels 450 mm in 0.5 seconds, causing the spacer to rise prematurely and blocking the product before it reaches its intended position, resulting in misalignment of the groups. Conversely, when the actual speed is higher than the standard speed (e.g., 1.1 m / s), the product travels 550 mm in 0.5 seconds, causing the spacer to rise later, resulting in the product exceeding its intended position and excessive spacing between groups. This positioning deviation caused by speed fluctuations accumulates continuously during production, eventually leading to chaotic stacking and even equipment jamming.

[0090] When using the encoder position triggering method of the present invention, the control system acquires the encoder pulse value in real time and uses the formula... The system calculates the actual travel distance of the product. Regardless of conveyor belt speed fluctuations, the system continuously monitors physical displacement. When the calculated distance reaches the set target value of 500mm, it immediately outputs a signal for the spacer to rise. Even if the conveyor belt speed drops to 0.9m / s, the system automatically extends the monitoring time until the product has actually traveled 500mm before triggering the action; conversely, when the speed increases to 1.1m / s, the system shortens the monitoring time, also triggering precisely at the 500mm position. This triggering mechanism transforms the judgment criterion for action execution from "uncertain time" to "certain physical position," fundamentally eliminating the impact of speed fluctuations on positioning accuracy.

[0091] The comparison shows that the encoder position triggering method used in this invention maintains a positioning accuracy within ±1mm under fluctuating conveyor belt speed conditions, with reliable action connection and standardized stack arrangement. In contrast, the positioning deviation of the time-sequence triggering method can reach ±50mm or even greater, and worsens with increasing fluctuation amplitude. This comparison fully demonstrates the ingenuity of the triggering mechanism of this invention. Through precise closed-loop feedback of physical displacement, it significantly improves the robustness and adaptability of the system, solving the problem of decreased control accuracy caused by speed instability in existing technologies.

[0092] It should be understood that although this embodiment uses the partition plate lifting action as an example for explanation, the triggering mechanism is also applicable to other action units such as pushing action, turning action, and pre-clamping action. As long as it involves precise control scenarios based on displacement, the encoder position triggering method can be used to replace the traditional time-sequence triggering to obtain higher positioning accuracy and stability.

[0093] Example 7: To further verify the technical advantages of the automatic parameter generation mechanism in this invention, this embodiment constructs a comparison scenario to compare and analyze the automatic calculation method based on the parameter generation model adopted in this invention with the traditional manual configuration method in the prior art.

[0094] Specifically, on the same palletizing and grouping station production line, for the same new pallet type (packaging dimensions 395mm long, 198mm wide, and 183mm high, with 5 boxes arranged horizontally and 3 boxes arranged vertically, for a total of 5 layers), two different methods were used to change the configuration, and the key indicators of the entire process were recorded.

[0095] Scenario 1: Manual configuration method using existing technology.

[0096] This method relies entirely on the experience and manual operation of professional technicians. First, technicians need to stop the machine and open the PLC programming software and HMI configuration interface. For the conveyor mechanism parameters, technicians need to estimate the conveyor belt speed based on experience, manually input the values, and repeatedly test-run and adjust to match production capacity. For the separating mechanism parameters, technicians need to consult mechanical drawings and manually calculate the position of each separating plate. The calculation process is easily affected by human factors. For example, when calculating the position of separating plate 3, if the encoder proportional coefficient K is forgotten, it will lead to a deviation in the calculation result. Furthermore, the calculated values ​​must be manually entered into the interface one by one. If the wrong position is entered (such as entering the value of separating plate 3 into the input box of separating plate 4), it will cause grouping errors. For the pushing mechanism parameters, technicians need to measure the product height on-site, manually calculate the pusher return position, and manually set the servo drive speed percentage. For action sequence arrangement, technicians need to write or modify ladder diagram programs in the PLC, defining the logic for Actions 1 to 14. For example, they need to manually write the judgment logic for "outputting a Y signal when sensor S401 is triggered and the encoder pulse reaches the X value." The programming process is time-consuming and prone to logical loopholes (such as missing interlock conditions). The entire configuration process involves calculating, inputting, and verifying dozens of parameters one by one, as well as modifying and debugging the control program. Actual measurements show that this manual configuration method takes an average of about 45 minutes, and due to the numerous manual calculation and input steps, the parameter error rate is as high as about 15% (such as numerical input errors, logical conflicts, etc.). Once a parameter error occurs, the machine must be stopped to troubleshoot, further extending the debugging time. Furthermore, this method requires extremely high operator skills and must be performed by professional technicians with PLC programming capabilities and equipment debugging experience; ordinary operators cannot complete it.

[0097] Scenario 2: Using the automatic parameter generation method of the present invention.

[0098] This method achieves fully automated configuration based on a parameter generation model. The operator only needs to input a small amount of descriptive information (such as material size and arrangement quantity) on the human-machine interface, and after clicking "confirm," the system automatically executes subsequent steps. The parameter calculation module instantly and accurately calculates a complete set of parameters, including the position of the partition plate, the push plate stroke, and the pre-clamping position, based on built-in formulas. The calculation process strictly follows physical rules, eliminating human calculation errors. The action sequence arrangement module automatically arranges the action sequence based on the descriptive information, requiring no manual coding. The system automatically performs validity checks, blocking illegal parameters. Finally, the operator clicks "one-click delivery," and the system sends the formula data package to the PLC in one go. Actual testing shows that this automatic generation method, from inputting information to the parameters taking effect, takes only about 2 minutes, with a parameter error rate close to 0% (due to the algorithm being fixed and validated). Furthermore, the operational threshold is extremely low; ordinary operators can complete the process independently after simple training.

[0099] As can be seen from the comparison, the automatic generation method of this invention reduces the model changeover time from 45 minutes to 2 minutes, improving efficiency by over 95%; it reduces the parameter error rate from 15% to nearly 0%, significantly improving system stability; and it lowers the skill requirement from "professional technicians" to "ordinary operators," greatly reducing labor costs and dependence. The fundamental reason for this significant advantage is that this invention solidifies the "experienced knowledge," "calculation rules," and "logical judgments" originally scattered in the minds of technicians into the algorithmic logic within the parameter generation model, achieving a qualitative leap from "manual discrete processing" to "system integrated automation." In manual configuration methods, the calculation, input, and verification of each parameter require manual intervention; any error in any step leads to overall failure, and the sequential execution of each step results in accumulated time consumption. In contrast, the automatic generation method of this invention processes all steps uniformly through the model, achieving accurate calculation, automatic verification, and integrated distribution. Parallel processing significantly reduces time, and the consistency of the algorithmic logic ensures the accuracy and reproducibility of the results. This comparative result fully demonstrates the inventiveness of the "automatic generation" feature of this invention, which not only improves efficiency but also fundamentally reconstructs the operation mode of equipment changeover, solving the core pain points of low efficiency, error-proneness, and high threshold of existing technologies.

[0100] Example 8: This embodiment provides a device for generating equipment control parameters, which is used to implement the equipment control parameter generation methods described in embodiments 1 to 7 above. This device can be a standalone computer device, such as an industrial control computer, a programmable logic controller (PLC), an embedded controller, or a server, or it can be a control unit integrated into a palletizing and grouping station control system.

[0101] The device includes a processor and memory. The processor is the core computing unit, responsible for executing instructions in the computer program, performing data operations, logical judgments, and generating control instructions. The processor can be a general-purpose processor, such as a Central Processing Unit (CPU) or a Microcontroller Unit (MCU), or a dedicated processor, such as a Digital Signal Processor (DSP), a Field-Programmable Gate Array (FPGA), or a System-on-a-Chip (SoC). The memory stores the computer program and the data required during program execution, such as descriptions of target permutation patterns, algorithmic logic for parameter generation models, and generated sets of device control parameters and control action sequences. The memory can include volatile memory (such as Random Access Memory, RAM) and non-volatile memory (such as Read-Only Memory (ROM), Flash memory, Hard Disk Drive (HDD), and Solid State Drive (SSD). The processor and memory are connected via a communication bus (such as a PCIe bus, I2C bus, or SPI interface) to achieve high-speed data transmission and instruction exchange.

[0102] Specifically, the memory stores a computer program that, when executed by the processor, implements the steps described in Embodiment 1: obtaining descriptive information of the target arrangement pattern; and automatically generating a set of device control parameters and a sequence of control actions based on the descriptive information using a parameter generation model. When the device starts running, the processor reads the computer program code from the memory and executes it according to the logical order of the code. First, the processor obtains the descriptive information of the target arrangement pattern input by the operator through a human-machine interface (such as a touch screen, keyboard, or barcode scanner) or a communication interface (such as Ethernet or serial port), and temporarily stores this information in the data buffer of the memory. Subsequently, the processor calls the parameter generation model algorithm pre-stored in the memory to parse and calculate the descriptive information, generating a complete set of device control parameters and a sequence of control actions. Finally, the processor sends the generated parameters and sequence to the device controller (such as a PLC) through the communication interface to drive the device to execute.

[0103] In one embodiment, the device includes a parameter calculation module and an action sequence arrangement module.

[0104] Specifically, when the processor executes the code segment corresponding to this module, it calls preset parameter calculation formulas (such as the separator position formula and the pusher stroke formula) to perform numerical calculations on data such as material size and arrangement quantity in the description information, and outputs specific numerical parameters. The action sequence arrangement module is used to arrange and control action sequences according to the description information. When the processor executes the code segment corresponding to this module, it calls preset action arrangement logic (such as independent arrangement of action groups and parallel and interleaved operation mechanism of action units) to perform logical judgments on data such as arrangement mode and product conveying direction in the description information, and outputs the action execution order, trigger conditions and interlocking relationships. It should be understood that although this embodiment describes the parameter calculation module and the action sequence arrangement module as two independent functional modules, in actual hardware implementation, they can be executed serially by the same processor, executed in parallel by different cores in a multi-core processor, or implemented separately by different hardware chips (such as one CPU for parameter calculation and one FPGA for action arrangement), as long as the corresponding functions can be achieved. This modular design makes the software logic of the device clear, easy to maintain and upgrade, and also facilitates flexible deployment according to actual hardware resources.

[0105] Through the configuration of the above hardware architecture and functional modules, the device in this embodiment can efficiently and stably execute the equipment control parameter generation method, solidifying the complex process that originally relied on manual programming and debugging into automated software and hardware collaborative processing, which significantly improves changeover efficiency and production stability.

[0106] Example 9: This embodiment provides a computer-readable storage medium, which serves as the physical carrier for the software logic of the device control parameter generation method of the present invention, and realizes the solidification, distribution and deployment of the algorithm.

[0107] Specifically, a computer-readable storage medium can be any physical entity or device containing memory and capable of storing computer program instructions. The medium stores a computer program, which, when executed by a processor, implements the steps described in Embodiment 1: obtaining descriptive information of the target arrangement pattern; and automatically generating a set of device control parameters and a sequence of control actions based on the descriptive information using a parameter generation model. When the medium is inserted into or connected to any device with computing capabilities (such as an industrial computer, PLC controller, or embedded system), the processor in the device reads the program code on the medium and performs operations and control according to the logic defined in the code, thereby transforming the device into a dedicated control terminal capable of implementing the method of this invention. This combination of "medium + processor" allows the technical solution of this invention to be detached from specific hardware constraints and flexibly deployed in different production line control systems in software form, greatly improving the versatility and portability of the solution.

[0108] It should be understood that computer-readable storage media can take many forms, and this embodiment is not limited to any particular form. For example, the medium can be a portable storage medium, such as a read-only memory (ROM), random access memory (RAM), flash drive, portable hard drive, optical disc (CD-ROM, DVD-ROM), or magnetic disk. These media are easy to carry and distribute, and operators can physically plug and unplug the medium storing the program code of this invention to different production line control terminals to achieve rapid algorithm import. The medium can also be a fixed storage medium, such as a server hard drive, a solid-state drive (SSD) inside an industrial control computer, or onboard Flash in an embedded system. These media are typically used for long-term storage and operation and are suitable as the core storage unit of a production line control system. In addition, the medium can also be a cloud storage medium or a network storage medium, where the program code is stored on a remote server or cloud database, and the control terminal remotely downloads and executes the code via network communication protocols (such as Ethernet, Wi-Fi). This form facilitates remote algorithm upgrades and synchronous updates across multiple terminals. Regardless of the physical form used, as long as the medium can stably store computer program instructions and allow the processor to read and execute them, it falls within the scope of this embodiment.

[0109] By providing a computer-readable storage medium, this invention achieves both "software-based" and "standardized" technical solutions. On one hand, the medium solidifies the core technologies—complex parameter generation model algorithms, parameter calculation formulas, and action orchestration logic—into standard program code, avoiding distortion or omissions in the algorithm logic during manual transmission and ensuring consistent technical effects across different production lines. On the other hand, as an independent commodity, the medium can be produced, sold, and licensed independently of specific palletizing and grouping station equipment. Users only need to purchase the medium and install it on existing equipment to grant the equipment the adaptive switching capabilities described in this invention, without needing to repurchase the entire hardware system, significantly reducing the cost and barriers to technology upgrades. This embodiment provides a practical and feasible platform for the commercial promotion and large-scale application of the method of this invention, further broadening the scope of protection and application scenarios of the technical solution.

[0110] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the embodiments of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application. Any changes 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 protection scope of this application.

Claims

1. A method for generating equipment control parameters for a palletizing and grouping station, characterized in that, The method includes: Obtain descriptive information about the target arrangement pattern; Based on the described information, a set of device control parameters and a sequence of control actions are automatically generated through a parameter generation model.

2. The method according to claim 1, characterized in that, The parameter generation model includes a parameter calculation module and an action sequence arrangement module; The parameter calculation module is used to calculate the device control parameter set based on the description information; The action sequence arrangement module is used to arrange control action sequences according to the description information.

3. The method according to claim 2, characterized in that, The action sequence orchestration module is configured with multiple action groups, and each action group can be enabled or disabled independently. Each action group independently arranges multiple action units, and each action unit uses the position signal detected by the encoder as the start condition; at least some of the action units have overlapping execution periods, and the transfer of control authority between action units with overlapping execution periods is achieved through state transmission. After completing its own task, the current action unit releases control over the steering mechanism and triggers the next action unit to acquire the control authority.

4. The method according to claim 3, characterized in that, Each action unit includes a parameter parsing layer and an action execution layer; The parameter parsing layer parses the action unit into a corresponding action mode based on the action type and product conveying direction; the action modes include disabled mode, straight-through mode, turning mode, interval baffle mode and spacing control mode; Specifically, when the action type is a disabled type, it is parsed as the disabled mode; when the action type is a forward type and the product conveying direction is consistent with the product orientation required by the action type, it is parsed as the straight-through mode; when the action type is a forward type and the product conveying direction is inconsistent with the product orientation required by the action type, it is parsed as the turning mode; when the action type is a separation type, it is parsed as the interval baffle mode; and when the action type is a spacing control type, it is parsed as the spacing control mode.

5. The method according to claim 4, characterized in that, The execution logic for each action mode is as follows: The disabled mode: marks the current action unit as running, allows the next action unit to start and take over the control of the steering mechanism, and terminates the current action unit; The straight-through mode: Start the conveyor belt, calculate the product's travel distance on the conveyor belt based on the encoder, reduce the conveyor belt speed when the travel distance reaches the deceleration distance set value, determine that feeding is complete when the travel distance reaches the box inlet displacement set value, stop the conveyor belt and allow the next action unit to start; The steering mode is as follows: the conveyor belt is started, the product travels on the conveyor belt based on the encoder, and when the travel distance reaches the set value of the box displacement, the steering cylinder is controlled to perform a steering action according to the preset configuration to adapt to products of different sizes. The current action unit ends after the product is detected to have passed the impact sensor. The interval baffle mode: the travel distance of the roller conveyor belt is calculated based on the encoder, and when the travel distance reaches the set target value, the interval baffle rise signal is output. The spacing control mode is as follows: the chain conveyor belt is stopped, and the next action unit is allowed to start after the roller conveyor belt has traveled a set distance.

6. The method according to claim 3, characterized in that, The method further includes: After the last product in all action units passes the sensor upon impact, the distance traveled by the last box is calculated based on the encoder; the formula for calculating the distance L of the last box is: in, This represents the current encoder pulse value. The starting encoder pulse value is D, where D is the drum diameter. The total number of pulses for one revolution of the encoder; when the last box travels a set distance, the entire sequence of control actions is completed.

7. The method according to claim 2, characterized in that, The parameter calculation module calculates at least one of the following parameters based on the material size and arrangement quantity in the description information: conveying mechanism parameters, separating mechanism parameters, pushing mechanism parameters, pre-clamping mechanism parameters, and carrier configuration parameters. The conveying mechanism parameters include conveyor belt speed settings and steering cylinder configurations. The conveyor belt speed settings include high speed, medium speed, and low speed. The steering cylinder configurations include multiple configuration values, each corresponding to a different combination of cylinder actions to adapt to products of different sizes. The separation mechanism parameters include the separation plate position parameters, specifically the position of the separation plate n. The calculation formula is: in, The reference distance from partition 1 to the impact completion sensor. For product packaging width, The spacing between the partitions, This is the encoder scaling factor; The parameters of the pushing mechanism include the parameters of the vertical push plate and the parameters of the horizontal pusher; The pre-clamping mechanism parameters include clamping position parameters and positioning mode parameters; the positioning mode parameters include positioning detection mode parameters and deceleration positioning mode parameters; the positioning detection mode parameters are used to configure the triggering conditions for the push-in operation; the deceleration positioning mode parameters are used to configure the motion control mode of the pre-clamping mechanism. The vehicle configuration parameters include position parameters and motion parameters of multiple servo drives; the position parameters include clamping position, opening position, and releasing position of each servo drive; the motion parameters include running speed parameters, acceleration parameters, and deceleration parameters; wherein, the position parameters of the rear positioning servo include limit position parameters; and the position parameters of the front positioning servo include trigger position parameters.

8. The method according to claim 1, characterized in that, Before sending the device control parameter set and the control action sequence to the device controller, the method further includes: Perform a validity check on the entire set of parameters; if the check fails, prevent the parameters from being issued, display an error message, and lock the device from starting. The legality verification includes at least one of the following: the parameter must not be negative, the position parameter must not exceed the mechanical travel range, the infeed displacement is greater than the deceleration distance, the partition plate number is within its corresponding valid range, the action type is its corresponding valid type, and the steering cylinder configuration is its corresponding valid configuration value.

9. A device for generating equipment control parameters, characterized in that, It includes a processor and a memory, the memory storing a computer program that, when executed by the processor, implements the steps of the method as described in any one of claims 1-8.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by a processor, it implements the steps of the method as described in any one of claims 1-8.

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