Procambarus clarkii intelligent processing device and processing method thereof

Abstract

The application provides a crayfish intelligent processing device and a processing method thereof, and belongs to the technical field of aquatic product processing. The device comprises a rack, a double-channel conveying and clamping mechanism arranged on the rack, a de-shelled line processing mechanism, a head-removing and cutting mechanism, an open-back and de-gill composite mechanism, an electric control system, a visual monitoring unit and a state sensing unit. The electric control system adopts a distributed architecture of upper and lower computers, and is internally provided with duplex interlocking scheduling logic and hierarchical abnormal linkage processing logic, which are used for coordinating the alternating operation of the double channels, and fusing visual and hardware sensing data to determine the processing state and abnormal working condition in real time. The device supports automatic switching of multiple processing modes, can intelligently match processing parameters according to the size of the crayfish body, and realizes self-adaptive control of the open-back depth through mechanical linkage and visual feedback correction. The application significantly improves the processing efficiency, operation reliability and working condition adaptability of the equipment, and meets the automatic primary processing needs of crayfish in small and medium-sized catering scenes.

Description

Technical Field

[0001] This invention relates to the field of aquatic product processing technology, and in particular to an intelligent crayfish processing device and its processing method. Background Technology

[0002] With the booming development of my country's catering industry, the market consumption of crayfish as a specialty aquatic ingredient continues to expand, particularly in regional catering markets. The entire crayfish industry chain has reached a market scale of hundreds of billions of yuan. The initial processing of crayfish is the preparatory stage for subsequent cooking and deep processing. Core procedures include removing the shrimp vein, head, back, and gills. Currently, this stage still heavily relies on manual labor, and the overall processing methods fall into two categories: one is the processing of shrimp tail products, primarily frozen and takeout shrimp tails, which results in high material loss and low unit efficiency; the other is the processing of whole shrimp dishes, represented by whole shrimp dishes for dine-in, which requires high precision in preserving the shrimp's shape and is more difficult to operate. Both processing scenarios share the common problems of high reliance on manual labor and low standardization, becoming a core bottleneck restricting the improvement of industry efficiency. Therefore, the need for automation upgrades in the initial processing of crayfish is increasingly urgent.

[0003] The existing purely manual initial processing model suffers from multiple drawbacks in actual operation and can no longer support the large-scale operation and quality upgrades of catering businesses. From the perspective of operating costs and efficiency, skilled initial processing workers have high labor costs, with significant labor shortages during peak seasons. Temporary workers further drive up wage premiums, and labor costs account for a high proportion of store operating costs, continuously squeezing the profit margins of businesses. At the same time, the processing capacity per person per unit time is limited, making it difficult to match the concentrated order demand during peak hours. The initial processing speed directly determines the store's food preparation efficiency, and during peak periods, insufficient processing capacity often leads to problems such as order limits and slow food preparation, becoming a core constraint on revenue growth. From the perspective of quality standardization, there are significant individual differences in manual operation. Processing parameters such as the position of the head, the depth of the back opening, and the completeness of shrimp vein removal are difficult to standardize, resulting in uneven flavor and inconsistent appearance of the finished products. This is not conducive to building a standardized brand image for stores and increases the difficulty of replicating and promoting chain stores. From a hygiene and management perspective, repeated manual handling of food, coupled with the damp and oily environment in the kitchen, poses a high risk of cross-contamination and makes food safety traceability difficult. Furthermore, the relevant processing procedures have high skill thresholds, and the training period for new employees is long. In addition, the turnover rate of employees in the catering industry is generally high, and personnel turnover can easily lead to fluctuations in processing quality, further increasing the management costs of stores.

[0004] Currently, some automated equipment for the initial processing of crayfish has appeared on the market. While single-station models have verified the technical feasibility of automated initial processing, significant technical shortcomings remain in practical commercial applications. Regarding operational efficiency, in the single-station serial operation mode, there is a time delay between manual feeding and machine processing, resulting in long equipment idle times. The processing capacity per unit time is insufficient to meet the concentrated order demands of peak nighttime hours, limiting overall efficiency improvement. In terms of process integration, most existing equipment lacks comprehensive functionality, with low integration of processes such as back-opening and gill removal. Multi-process linkage adaptability is poor, failing to achieve a complete "one-time clamping, full-process processing" workflow. Manual assistance is still required to complete the remaining steps, indicating insufficient automation and failing to fully unleash the equipment's processing capacity.

[0005] Furthermore, existing first-generation automated equipment suffers from significant deficiencies in intelligent monitoring and safety protection, lacking real-time perception of processing status. During operation, it often fails to automatically identify and promptly stop abnormal conditions such as shrimp detachment or processing component jamming, easily leading to material waste, blade damage, and even potential equipment safety accidents. Simultaneously, the existing equipment's user interface and control system are relatively simple, failing to meet the differentiated processing needs of different dishes or crayfish sizes, and lacking the ability to flexibly switch between different process combinations, making it difficult to adapt to the multi-variety, multi-batch processing scenarios in restaurant kitchens. Due to the combined problems of complex structure, high cost, poor adaptability, inconvenient maintenance, and low level of intelligence in these existing technologies, they cannot truly meet the actual needs of small and medium-sized catering businesses for equipment that is "cost-controllable, stable, durable, and easy to operate." Summary of the Invention

[0006] In view of this, the purpose of the present invention is to provide a crayfish intelligent processing device and processing method, which effectively improves the operating efficiency, working condition adaptability and operational reliability of crayfish processing equipment by using a multi-source sensing system that integrates visual monitoring and hardware sensing, combined with dual-station intelligent scheduling, hierarchical abnormal linkage processing and multi-mode adaptive control.

[0007] The technical solution adopted by this invention to solve its technical problem is: A crayfish intelligent processing device and method are provided, comprising: a frame, and a dual-channel conveying and clamping mechanism, a deveining processing mechanism, a head-removing and cutting mechanism, a back-opening and gill-removing composite mechanism, and an electronic control system mounted on the frame. The device is characterized by further including a visual monitoring unit and a status sensing unit. The visual monitoring unit is located at the bottom of the processing area of ​​the frame, and its image acquisition field simultaneously covers the left and right processing channels of the dual-channel conveying and clamping mechanism. It is used to collect images of the crayfish's in-situ status and processing execution status at each workstation in real time and output visual detection signals. The status sensing unit is configured at the action execution ends of the dual-channel conveying and clamping mechanism and each processing mechanism, and is used to collect the operating status parameters of each execution component in real time and output status feedback signals. The electronic control system is communicatively connected to the visual monitoring unit, the status sensing unit, the dual-channel conveying and clamping mechanism, and the multi-processing module, respectively, and is used to receive visual detection signals and status feedback signals. When an abnormality is detected in the visual detection signal or status feedback signal, it triggers a protection action for the corresponding processing channel.

[0008] Preferably, the electronic control system adopts a distributed control architecture of upper and lower computers, including a lower computer real-time control unit and an upper computer interaction unit. The signal output terminal of the visual monitoring unit is connected to the lower computer real-time control unit. The lower computer real-time control unit is electrically connected to the dual-channel conveying clamping mechanism, the shrimp deveining processing mechanism, the head removal and cutting mechanism, and the back opening and gill removal composite mechanism. It has built-in dual-station interlocking scheduling logic and abnormal linkage processing logic, which can receive the detection data of the visual monitoring unit and determine the abnormal states of shrimp body detachment, processing defects and station jamming. When an abnormality is determined, it triggers the shutdown protection action of the corresponding processing channel and reports the abnormal information to the upper computer interaction unit.

[0009] Preferably, the visual monitoring unit includes an embedded AI vision controller and a camera assembly. The camera assembly is arranged at a downward angle below the processing platform, and a transparent protective partition is set between the camera and the processing area above. The detection points of the visual monitoring unit include at least a head removal processing station, a back opening processing station, and a conveying and clamping station. The visual monitoring unit has a built-in threshold segmentation and contour detection algorithm based on the HSV color space. By extracting the area, centroid position, and edge features of the shrimp body contour, and comparing them with preset standard parameters, it determines the integrity of the shrimp head separation, the effectiveness of the shrimp back cutting, and the shrimp body detachment status.

[0010] Preferably, the status sensing unit includes limit switches configured at both ends of the conveying track, angle feedback modules configured at each drive servo motor, and current detection modules configured at the drive DC motor; the electronic control system determines the station position status based on the limit switch trigger signal, determines the positioning accuracy of the chuck and machining blade based on the angle feedback module signal, and determines whether the motor is stalled or overloaded based on the current detection module signal.

[0011] Preferably, the dual-station interlocking scheduling logic is configured such that only one processing channel is allowed to execute the complete processing flow at any given time. After receiving the start command, the other channel only performs the shrimp pre-clamping action and enters the queuing waiting state. After the current active channel completes its processing, the queuing channel is automatically promoted to the active channel and skips the repeated clamping steps, realizing seamless continuous operation between the two stations. The abnormal linkage handling logic adopts a hierarchical processing mechanism. When a hard fault is determined to be shrimp detachment, station jamming, or motor stall, all motion outputs of the corresponding channel are immediately stopped and an audible and visual alarm is triggered. When a soft fault is determined to be processing accuracy deviation or motion angle offset, an abnormal log is recorded and the processing speed of the corresponding channel is reduced. At the same time, a warning message is pushed to the host computer interaction unit.

[0012] Preferably, the lower-level real-time control unit is equipped with at least four processing mode logics, including at least a large all-around mode, a small all-around mode, a shrimp mode, and a simple mode, each corresponding to different processing procedure combinations; the visual monitoring unit can automatically adjust the number of detection stations, image acquisition area, judgment threshold, and anomaly handling logic according to the currently selected processing mode.

[0013] Preferably, a mechanically linked back-opening height adjustment component is provided between the head-removing and cutting mechanism and the back-opening and gill-removing composite mechanism. The adjustment component includes an eccentric wheel, a back-opening adjustment plate, and a lever fulcrum that are coaxially driven with the head-removing and cutting mechanism. The working height of the back-opening saw blade is adjusted in linkage with the angular displacement of the head-removing and cutting action. The electronic control system can perform program fine-tuning compensation on the linkage adjustment reference parameters based on the back-opening depth detection results collected by the visual monitoring unit and the actual rotation angle of the head-removing and cutting mechanism collected by the state perception unit, forming a dual depth adjustment closed loop of mechanical self-adaptation and software feedback correction.

[0014] Preferably, the frame adopts a layered layout, with the lower layer being a closed transmission cavity and precision transmission components installed upside down, and the upper layer being an open processing area. The two are physically separated by a partition. The electronic control system is located at the top of the frame, and the detection ends of the visual monitoring unit and the status sensing unit are both located below the partition. The dual-channel conveying and clamping mechanism includes two sets of independent synchronous belt conveyor tracks and two stepper motors. The two sets of tracks are symmetrically arranged in the middle of the frame, and the two stepper motors are respectively mounted on the corresponding tracks on the frame and can drive the corresponding tracks to rotate, thereby driving the shrimp clamping unit. The machine moves back and forth along the frame axis, with two sets of tracks operating independently to coordinate alternating dual-station operations. Flexible rubber strips are symmetrically attached to both sides of the back-opening and gill-removing composite mechanism's saw blade. These flexible strips rotate synchronously with the saw blade, intermittently pressing down on the shrimp's claws in a flexible contact manner. A protective cover is provided on the outside of the gill-removing component of the back-opening and gill-removing composite mechanism. A rinsing hole is provided on the protective cover corresponding to the gill-removing component. A rinsing water pump is correspondingly installed on the frame, with its outlet connected to the rinsing hole, enabling the rinsing and cleaning of the processed crayfish.

[0015] A processing method based on the aforementioned intelligent crayfish processing device includes the following steps: S1. System initialization: The system is powered on and reset. The electronic control system initializes each processing channel, vision monitoring unit and status sensing unit. After completing the self-test, it enters the standby state. S2. Feeding and Scheduling: The operator places crayfish into the corresponding processing channel and triggers the start command. The electronic control system determines the channel status through the dual-station interlock scheduling logic. If there is no active channel, the processing process is started directly. If there is an active channel, the channel to be started is controlled to perform a pre-clamping action and enter the queue. S3. Processing steps: The active channel feeds the shrimp to the shrimp deveining station, head removal and cutting station, and back opening and gill removal station in a preset sequence, and the corresponding processing mechanism completes the processing actions of each step in sequence. S4. Multi-source fusion monitoring: Throughout the entire processing process, the visual monitoring unit collects shrimp images in real time according to the workstation rhythm and outputs visual detection signals, while the status perception unit collects the operating parameters of each execution component in real time and outputs status feedback signals. The electronic control system integrates the two types of signals to complete the real-time judgment of operating status and processing quality. S5. Abnormal Handling and Continuation: When the electrical control system determines that an abnormal state exists, it triggers the protection action of the corresponding processing channel and reports the abnormal information; when no abnormality is determined, the channel resets and unloads after completing all processes, and the queuing channel automatically continues to start the processing flow.

[0016] Preferably, in step S4, when the visual monitoring unit identifies the size difference of the crayfish in the current channel, the lower-level real-time control unit automatically matches the processing parameters corresponding to the size. The processing parameters include the clamping opening and closing angle, conveying speed, blade cutting stroke, and back opening depth linkage reference value. In step S5, a graded abnormality handling mechanism is adopted: when it is determined to be a hard fault type such as shrimp body falling off, workstation jamming, or motor stalling, all motion output of the corresponding channel is immediately stopped and an audible and visual alarm is triggered. At the same time, the upper-level computer displays the fault code and troubleshooting guidance. When it is determined to be a soft fault type such as processing accuracy deviation or movement angle offset, an abnormality log is recorded and the processing speed of the corresponding channel is reduced. When multiple shrimp bodies are processed and qualified, the speed is automatically restored to the standard processing speed.

[0017] The beneficial effects of this invention are: This invention provides an intelligent crayfish processing device and method. It constructs a multi-source fusion real-time monitoring system through a visual monitoring unit and a status perception unit, coupled with a distributed control architecture between upper and lower computers, achieving comprehensive closed-loop perception of the crayfish's on-site status, processing quality, and hardware operating conditions. Relying on dual-station interlocking scheduling logic, it can precisely coordinate seamless alternating operations between two channels, effectively eliminating equipment idle waiting and significantly improving overall processing efficiency. Employing a graded anomaly linkage handling mechanism, it can execute differentiated protection strategies for different fault levels, ensuring equipment and material safety while reducing unnecessary downtime. Simultaneously, it supports intelligent switching between multiple processing modes and adaptive parameter matching based on crayfish specifications, dynamically adjusting detection strategies and operating parameters, significantly improving the equipment's adaptability and operational reliability, effectively overcoming the shortcomings of traditional crayfish processing equipment such as insufficient intelligence, delayed anomaly response, and weak flexible processing capabilities. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of a crayfish intelligent processing device according to Embodiment 1 of the present invention.

[0019] Figure 2 This is a reference diagram of the right-side three-dimensional structure of an intelligent crayfish processing device according to Embodiment 1 of the present invention.

[0020] Figure 3 This is a schematic diagram of the internal structure of a crayfish intelligent processing device according to Embodiment 1 of the present invention.

[0021] Figure 4 This is a cross-sectional view of a crayfish intelligent processing device according to Embodiment 1 of the present invention.

[0022] Figure 5 This is a display diagram of the electrical control system of a crayfish intelligent processing device according to Embodiment 1 of the present invention.

[0023] Figure 6 This is a diagram of the distributed control architecture of a crayfish intelligent processing device according to Embodiment 1 of the present invention.

[0024] Figure 7 This is a flowchart illustrating the usage of an intelligent crayfish processing device according to Embodiment 1 of the present invention.

[0025] Figure 8 This is a dual-channel interlocking and queuing timing diagram of a crayfish intelligent processing device according to Embodiment 1 of the present invention.

[0026] Figures 9-11 This is a physical reference diagram of an intelligent crayfish processing device according to Embodiment 1 of the present invention.

[0027] In the diagram: 1. Frame; 2. Dual-channel conveying and clamping mechanism; 3. Shrimp deveining processing mechanism; 4. Head removal and cutting mechanism; 5. Back opening and gill removal composite mechanism; 51. Back opening saw blade; 52. Flexible rubber strip; 6. Electrical control system; 7. Visual monitoring unit; 8. Status sensing unit; 9. Adjustment component; 10. Rinse water pump; 11. Protective cover.

[0028] It should be noted that these accompanying drawings and textual descriptions are not intended to limit the scope of the invention in any way, but rather to illustrate the concept of the invention to those skilled in the art by referring to specific embodiments. Detailed Implementation

[0029] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] Example 1

[0031] like Figures 1-11 As shown, a crayfish intelligent processing device includes: a frame 1, a dual-channel conveying and clamping mechanism 2, a deveining processing mechanism 3, a head-removing and cutting mechanism 4, a back-opening and gill-removing composite mechanism 5, a visual monitoring unit 7, a status sensing unit 8, and an electronic control system 6. This device is designed for the initial processing of crayfish in small and medium-sized catering establishments, integrating four major processes: deveining, head removal, back opening, and gill removal. It improves processing efficiency and operational reliability through alternating dual-station operation and multi-source intelligent monitoring. Furthermore, such as Figure 2As shown, the frame 1 is assembled from industrial aluminum profiles, resulting in a lightweight, rigid, and highly versatile overall structure. To ensure operational stability in the oily and humid environment of the kitchen, the frame 1 adopts a layered layout: the lower layer is a closed transmission cavity for inverted installation of precision transmission components (such as stepper motors, synchronous belts, and guide rails); the upper layer is an open processing area for arranging various processing components and shrimp conveying channels. The lower transmission cavity and the upper processing area are physically separated by partitions, structurally preventing wastewater and shrimp shell debris generated during processing from entering the precision transmission components, effectively solving the defect of traditional equipment transmission components being easily contaminated and jammed.

[0032] Furthermore, such as Figure 3 As shown, the dual-channel conveying and clamping mechanism 2 is symmetrically arranged in the middle of the frame 1, including two sets of independent synchronous belt conveying tracks and two stepper motors. The two stepper motors independently drive the corresponding tracks to move, causing the shrimp clamping unit to reciprocate along the axial direction of the frame 1. The two sets of conveying tracks operate independently of each other, providing structural support for alternating dual-station operations. Compared with ordinary belt conveyors, synchronous belt drives have high positioning accuracy, less slippage, and fast start-stop response, which can accurately stop the shrimp at each processing station and reduce processing misalignment deviation. The two sets of conveying tracks operate independently of each other, and in conjunction with the alternating dual-station operation logic, they realize asynchronous start-stop of the two channels, effectively utilizing the process time difference to eliminate equipment idle waiting.

[0033] Furthermore, such as Figure 3 As shown, each set of conveyor tracks is equipped with a shrimp-adaptive fixing clamping assembly, which adopts a concentric symmetrical double-clamp synchronous clamping structure. Using a fixed base plate as a carrier, the clamps on both sides open and close synchronously through servo motor transmission, ensuring that the shrimp is centered and evenly stressed. The clamping assembly adopts a dorsal and ventral bidirectional contouring and limiting design. The clamps are contoured and have a steel pin structure that conforms to the contour of the lobster's back and presses it firmly. The bottom is equipped with a shrimp tail seat and a ventral contouring block to conform to the curvature of the shrimp's abdomen. At the same time, the plate has limiting grooves to adapt to the shape of the shrimp, realizing a close-fitting fixation of non-standard irregularly shaped shrimp. Compared with single-point clamping, the limiting area is larger, the fit is higher, and the locking stability is stronger, effectively reducing the risk of shrimp flipping or shifting during processing. Structurally, it ensures the integrity of subsequent head removal, back opening, and gill removal processes.

[0034] Furthermore, the shrimp deveining mechanism 3 adopts a servo motor-driven clamping and pulling scheme, which is integrated into a synchronous belt linear guide rail. Functionally, it is divided into a drive unit, a transmission unit, an execution unit, and a mounting frame 1. The drive unit uses an MG996R metal gear digital servo motor, which has a large stall torque and high control precision, and can accurately adjust the opening and closing angle of the clamps. The transmission unit includes a multi-stage spur gear pair and a D-section transmission shaft. The servo motor power is transmitted to the D-shaped shaft after gear reduction and torque amplification. The left and right clamps are opened and closed synchronously through the flange top belt, eliminating circumferential transmission gaps and ensuring uniform clamping force on both sides. The transmission shaft is made of 304 food-grade stainless steel and is supported by deep groove ball bearings at both ends, making it suitable for the humid environment of aquatic product processing. The execution unit consists of symmetrical shrimp deveining clamps. The clamping point is selected at the connection between the shrimp tail and the shrimp body. Anti-slip sandpaper is attached to the clamping surface to increase static friction, taking into account both clamping reliability and shrimp meat integrity. The clamp base is made of 304 stainless steel wire-cut and the edges are rounded to reduce the shrimp meat breakage rate.

[0035] This mechanism employs hierarchical timing control. The complete process includes eight stages: standby, feed positioning, chuck closure, clamping and pressure holding, wire pulling, chuck slack-out, rapid reset, and cyclic waiting. The slide table feed position accuracy can reach ±0.5mm. It also features dual safety protection: load monitoring is achieved through servo motor current feedback; if the pulling load exceeds a preset threshold, the operation immediately stops and an alarm is triggered. Both ends of the slide table are equipped with photoelectric limit switches and mechanical hard limit switches for dual protection against collisions during travel.

[0036] Furthermore, such as Figure 4 As shown, the head-removing and cutting mechanism 4 is an integrated head-removing and material-ejecting composite structure. It adopts a gear-D-axis V-shaped blade cutting scheme, powered by a high-torque servo motor with a torque of 1160 kg·cm. After multi-stage spur gear meshing for speed reduction and torque amplification, the torque is transmitted to the D-shaped drive shaft, where the V-shaped blade is rigidly locked at the shaft end. The V-shaped blade pierces into the shrimp head gap at a fixed angle, accurately separating the shrimp head from the shrimp body. The edible shrimp claws can be completely preserved during processing, reducing food waste. The gear transmission output angle can be finely adjusted by the program to adapt to the head-removing position requirements of shrimp of different sizes. The mechanism is equipped with a fixed shrimp unloading baffle, without additional driving components. When the shrimp body clamping mechanism returns to its original position, the separated shrimp head slides relative to the stationary baffle and automatically peels off and falls off due to mechanical obstruction, eliminating the need for manual waste removal.

[0037] Furthermore, such as Figure 4As shown, a mechanically linked back-opening height adjustment component 9 is provided between the head-removing and cutting mechanism 4 and the back-opening and gill-removing composite mechanism 5. The adjustment component 9 includes an eccentric wheel, a back-opening adjustment plate, and a lever fulcrum that are coaxially driven with the head-removing and cutting mechanism 4. During the head-removing and cutting action, the D-shaped shaft rotates to generate angular displacement, which drives the adjustment plate and lever to move through the eccentric wheel, thereby adjusting the working height of the back-opening saw blade 51: when the blade deflects an additional 15°, the cam lifts the adjustment plate and lever, raising the saw blade to accommodate larger shrimp; when there is no additional deflection, the saw blade remains in a low position to accommodate smaller shrimp. The purely mechanical structure achieves adaptive adjustment of the back-opening depth for all sizes of shrimp.

[0038] Furthermore, such as Figure 4 As shown, the back-opening and gill-removing composite mechanism 5 is an integrated composite operation module, using a dual-output shaft DC motor as the single power core. It mainly consists of a back-opening saw blade 51 assembly, a shrimp-pressing claw blade, an O-type synchronous belt drive pair, a dual-station gill-brushing roller group, a protective cover 11, and a lever-linked adjustment base. One end of the dual-output shaft DC motor drives the back-opening saw blade 51 to rotate at high speed, completing the precise cutting of the shrimp's back shell. Flexible rubber strips 52 are symmetrically attached to both sides of the saw blade, rotating synchronously with the saw blade, intermittently pressing down on the shrimp claws in a flexible contact manner to avoid scratching the shrimp meat and ensure the integrity of the shrimp claws. The other end of the motor transmits power to the dual gill-brushing stations through the O-type synchronous belt, driving the two sets of gill-brushing rollers to rotate synchronously, cleaning and peeling the shrimp gills from both sides of the shrimp body. The gill-brushing station is equipped with a baffle plate and a protective cover 11 to prevent shrimp gill and shell debris from being rolled into the transmission structure, reducing the risk of equipment jamming. The protective cover 11 has a rinsing hole, and a rinsing water pump 10 is installed on the frame 1. The water outlet of the rinsing water pump 10 is connected to the rinsing hole on the protective cover 11 through a water supply pipe. The water outlet of the rinsing hole is directed towards the discharge section of the shrimp conveying path. When the shrimp completes the back-opening and gill removal process and is fed to the discharge position along the conveying track, the rinsing water pump 10 starts and sprays clean water through the rinsing hole to rinse and remove shrimp gill debris, shell residue and dirt attached to the surface of the shrimp, completing the final cleaning of the shrimp, improving the cleanliness of the finished product and reducing the subsequent manual cleaning process.

[0039] The entire composite mechanism is installed on the lever linkage adjustment base and is linked with the head removal and cutting mechanism 4. The overall height of the saw blade is automatically adjusted according to the size of the shrimp to ensure that the back opening depth and gill brushing position are always matched with the size of the shrimp.

[0040] Furthermore, such as Figure 1As shown, the visual monitoring unit 7 is located at the bottom of the processing area of ​​the rack 1, and its image acquisition field of view covers both the left and right processing channels simultaneously. It includes an embedded AI vision controller and a camera assembly. In this embodiment, the vision controller uses an embedded AI vision development board with a RISC-V architecture processor (1GHz), integrating 1 TOPSNPU computing power to support local lightweight AI inference. The camera is positioned at an upward angle below the processing platform, with a transparent protective partition between it and the processing area above, ensuring unobstructed view while preventing juice splashing. The detection points of the visual monitoring unit 7 at least cover the head removal processing station, the back-opening processing station, and the conveying and clamping station. It incorporates a threshold segmentation and contour detection algorithm based on the HSV color space: by extracting the area, centroid position, and edge features of the shrimp's contour, and comparing them with preset standard parameters... The system compares and determines the integrity of shrimp head separation, the effectiveness of shrimp back cutting, and the state of shrimp body detachment. The detection cycle is synchronized with the equipment's processing rhythm. After each station action is completed, an image acquisition and judgment are triggered, and the judgment results are transmitted to the lower-level computer of the electronic control system 6 in real time via UART serial port. In addition, the visual monitoring unit 7 has an automatic shrimp body size recognition function, which can identify the size grade of shrimp bodies in the current channel and feed it back to the electronic control system 6 to automatically match the corresponding processing parameters. At the same time, it can automatically adjust the number of detection stations, image acquisition area, judgment threshold, and abnormal handling logic according to the currently selected processing mode to adapt to the monitoring needs of different process combinations.

[0041] Furthermore, such as Figure 3 As shown, the state sensing unit 8 is configured at the action execution ends of the dual-channel conveying and clamping mechanism 2 and each processing mechanism, and is used to collect the operating status parameters of each execution component in real time, mainly including: Limit switches: There are 4 in total, which are respectively configured at the front and rear ends of the two sets of conveyor tracks. The electrical control system 6 determines the station position status based on the limit switch trigger signal.

[0042] Angle feedback module: configured in each drive servo, including chuck servo, shrimp line servo, and blade servo, used to provide feedback on the actual opening and closing angle of each actuator; the electronic control system 6 compares the feedback angle with the target angle, and when the deviation is greater than 5°, it is determined that the accuracy of the action is abnormal.

[0043] Current detection module: configured to drive DC motor (open-back gill-free motor) to collect motor operating current in real time and determine whether the motor is stalled or overloaded.

[0044] The electronic control system's six lower-level computers poll all status sensing nodes every 50ms, comparing the collected data with preset thresholds to provide hardware sensing basis for anomaly detection, forming a three-dimensional monitoring system together with visual detection signals.

[0045] Furthermore, the electronic control system 6 adopts a distributed control architecture of upper and lower computers, including a lower computer real-time control unit and an upper computer interaction unit, which respectively undertake the functions of real-time motion control and human-computer interaction.

[0046] The lower-level machine (Arduino Mega2560 as the control core, 16MHz main frequency) has ample I / O resources and real-time response capabilities. It is electrically connected to the dual-channel conveyor clamping mechanism 2, the shrimp deveining processing mechanism 3, the head removal and cutting mechanism 4, and the back-opening and gill removal composite mechanism 5, and is also connected to the signal output terminals of the vision monitoring unit 7 and the status sensing unit 8. The lower-level machine adopts a non-blocking state machine execution model. Each processing step corresponds to a state branch. Only one action command is initiated in a single main loop and returns immediately. The completion status of the action is determined by the arrival feedback signal of the status sensing unit 8, and the state jump is driven. When an abnormal judgment signal is received, the current state machine process is immediately interrupted and directly jumps to the safety protection state. The upper-level machine uses ESP32-S3 as the HMI master controller, equipped with a 1024×600 color touch screen, and runs the LVGL graphical interface framework. It is responsible for human-computer interaction, mode selection, status display, and output statistics. It communicates bidirectionally with the lower-level machine through the UART serial port.

[0047] The lower-level machine has built-in dual-station interlocking scheduling logic and exception handling logic: Dual-station interlocking scheduling logic: Only one processing channel is allowed to execute the complete processing flow at any given time. After receiving the start command, the other channel only performs the shrimp pre-clamping action and enters the queuing waiting state. After the currently active channel completes its processing, the queuing channel is automatically promoted to active channel and skips the repeated clamping steps, achieving seamless continuous operation between the two stations. The shrimp line servo and the head-removing blade servo share resources between the two channels. Interlocking scheduling ensures that only one channel can call them at any given time, avoiding resource contention.

[0048] Abnormal linkage handling logic: A hierarchical processing mechanism is adopted. When a hard fault is determined to be shrimp body detachment, workstation jamming, or motor stall, all motion outputs of the corresponding channel are immediately stopped and an audible and visual alarm is triggered. At the same time, a fault code and troubleshooting guidance are reported to the host computer. When a soft fault is determined to be processing accuracy deviation or motion angle offset, an abnormality log is recorded and the processing speed of the corresponding channel is reduced. At the same time, a warning message is pushed to the host computer. When multiple shrimp bodies are processed and qualified, the speed is automatically restored to the standard processing speed.

[0049] Furthermore, such as Figure 5As shown, the lower-level machine has at least four processing mode logics built-in, each corresponding to a different combination of processing steps: All-round mode (large) and All-round mode (small), which activate all four steps and are adapted to large and small shrimp respectively; Shrimp meat mode, which only activates the shrimp head removal and shrimp vein removal steps and is adapted to shrimp meat products; and Simple mode, which only activates the shrimp vein removal and shrimp back opening steps and is adapted to cooking scenarios that retain the shrimp head. Each mode corresponds to an independent state machine process. Mode switching only changes the combination of steps and parameters, without changing the underlying driving logic, thus achieving flexible processing.

[0050] Meanwhile, the electronic control system 6 can perform program-based fine-tuning compensation of the benchmark parameters of mechanical linkage adjustment based on the back opening depth detection results collected by the vision monitoring unit 7 and the actual rotation angle of the head-removing and cutting mechanism 4 collected by the state perception unit 8, forming a dual depth adjustment closed loop of mechanical self-adaptation and software feedback correction, further improving the back opening processing accuracy.

[0051] Based on the above-mentioned device, such as Figures 6-8 As shown, the intelligent crayfish processing method of this embodiment includes the following steps: S1. System initialization: The system is powered on and reset. The electronic control system 6 initializes each processing channel, the vision monitoring unit 7, and the status sensing unit 8. After completing the hardware self-test and parameter loading, it enters the standby state.

[0052] S2. Feeding and Scheduling: The operator places crayfish into the corresponding processing channel and triggers the start command. The electronic control system 6 determines the channel status through the dual-station interlock scheduling logic. If there is no currently active channel, the processing process is started directly. If there is an active channel, the system controls the channel to be started to perform a pre-clamping action and enter the queue.

[0053] S3. Processing steps: The active channel feeds the shrimp to the shrimp deveining station, head removal and cutting station, and back opening and gill removal station in a preset sequence. The corresponding processing mechanisms complete the processing actions of each step in sequence. During the processing, the head removal and cutting action adjusts the height of the back opening saw blade 51 synchronously through the mechanical linkage structure to adapt to the shrimp body specifications.

[0054] S4. Multi-source fusion monitoring: Throughout the processing, the visual monitoring unit 7 collects shrimp images in real time according to the workstation rhythm and outputs visual detection signals. The status perception unit 8 collects the operating parameters of each execution component in real time and outputs status feedback signals. The electronic control system 6 integrates the two types of signals to complete the real-time judgment of the operating status and processing quality. When the visual monitoring unit 7 identifies the current size difference of the shrimp, the lower-level machine automatically matches the corresponding processing parameters, including the clamping opening and closing angle, conveying speed, blade cutting stroke and back opening depth linkage reference value. At the same time, the visual monitoring unit 7 dynamically adjusts the detection strategy according to the current processing mode and skips the detection steps of inactive processes.

[0055] S5. Abnormal handling and continuation: When the electrical control system 6 determines that there is an abnormal state, it triggers the corresponding protection action and reports the abnormal information according to the hierarchical abnormal handling mechanism; when no abnormality is determined, the channel resets and unloads after completing all processes, and the queuing channel automatically resumes the processing flow.

[0056] Finally, it should be noted that the above description is merely a preferred embodiment of the present invention and is only used to illustrate the technical solution of the present invention, and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention are included within the scope of protection of the present invention.

[0057] In the description of this invention, it should be understood that the terms "upper", "lower", "upper end", "lower end", "upper surface", "lower surface", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing this 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, and therefore should not be construed as a limitation of this invention.

Claims

1. A smart crayfish processing device, comprising: The machine frame, along with a dual-channel conveyor clamping mechanism, a shrimp deveining processing mechanism, a head-removing and cutting mechanism, a back-opening and gill-removing composite mechanism, and an electronic control system mounted on the machine frame, are characterized by: further including a visual monitoring unit and a status sensing unit; the visual monitoring unit is located at the bottom of the processing area of ​​the machine frame, and its image acquisition field of view simultaneously covers the left and right processing channels of the dual-channel conveyor clamping mechanism, used to acquire images of the shrimp's in-situ status and processing execution status at each workstation in real time and output visual detection signals; the status sensing unit is configured at the action execution end of the dual-channel conveyor clamping mechanism and each processing mechanism, used to acquire the operating status parameters of each execution component in real time and output status feedback signals; the electronic control system is communicatively connected to the visual monitoring unit, the status sensing unit, the dual-channel conveyor clamping mechanism, and the multi-process processing module, used to receive visual detection signals and status feedback signals, and trigger the protection action of the corresponding processing channel when the visual detection signal or status feedback signal is abnormal.

2. The intelligent crayfish processing device as described in claim 1, characterized in that: The electronic control system adopts a distributed control architecture of upper and lower computers, including a lower computer real-time control unit and an upper computer interaction unit. The signal output terminal of the visual monitoring unit is connected to the lower computer real-time control unit. The lower computer real-time control unit is electrically connected to the dual-channel conveying and clamping mechanism, the shrimp deveining processing mechanism, the head removal and cutting mechanism, and the back opening and gill removal composite mechanism. It has built-in dual-station interlocking scheduling logic and abnormal linkage processing logic, which can receive the detection data of the visual monitoring unit and determine the abnormal states of shrimp body detachment, processing defects, and station jamming. When an abnormality is determined, it triggers the shutdown protection action of the corresponding processing channel and reports the abnormal information to the upper computer interaction unit.

3. The intelligent crayfish processing device as described in claim 2, characterized in that: The visual monitoring unit includes an embedded AI vision controller and a camera assembly. The camera assembly is positioned below the processing platform at a downward angle, and a transparent protective partition is installed between the camera and the processing area above. The detection points of the visual monitoring unit include at least a head removal processing station, a back opening processing station, and a conveying and clamping station. The visual monitoring unit incorporates a threshold segmentation and contour detection algorithm based on the HSV color space. By extracting the area, centroid position, and edge features of the shrimp body contour and comparing them with preset standard parameters, it determines the integrity of the shrimp head separation, the effectiveness of the shrimp back cutting, and the shrimp body's in-situ detachment status.

4. The intelligent crayfish processing device as described in claim 1, characterized in that: The state sensing unit includes limit switches at both ends of the conveying track, angle feedback modules on each drive servo motor, and current detection modules on the drive DC motor. The electrical control system determines the station's position status based on the limit switch trigger signal, determines the accuracy of the chuck and machining blade's movement based on the angle feedback module signal, and determines whether the motor is stalled or overloaded based on the current detection module signal.

5. The intelligent crayfish processing device as described in claim 2, characterized in that: The dual-station interlocking scheduling logic is configured so that only one processing channel can execute the complete processing flow at any given time. After receiving the start command, the other channel only performs the shrimp pre-clamping action and enters the queuing waiting state. After the current active channel completes its processing, the queuing channel is automatically promoted to active channel and skips the repeated clamping steps, realizing seamless connection of dual-station operations. The abnormal linkage handling logic adopts a hierarchical processing mechanism. When a hard fault is determined to be shrimp detachment, station jamming, or motor stall, all motion outputs of the corresponding channel are immediately stopped and an audible and visual alarm is triggered. When a soft fault is determined to be processing accuracy deviation or motion angle offset, an abnormal log is recorded and the processing speed of the corresponding channel is reduced. At the same time, a warning message is pushed to the host computer interaction unit.

6. The intelligent crayfish processing device as described in claim 2, characterized in that: The lower-level real-time control unit is equipped with at least four processing mode logics, including at least a large all-around mode, a small all-around mode, a shrimp mode, and a simple mode, each corresponding to different processing procedure combinations; the visual monitoring unit can automatically adjust the number of detection stations, image acquisition area, judgment threshold, and anomaly handling logic according to the currently selected processing mode.

7. The intelligent crayfish processing device as described in claim 2, characterized in that: A mechanically linked back-opening height adjustment component is provided between the head-removing and cutting mechanism and the back-opening and gill-removing composite mechanism. The adjustment component includes an eccentric wheel, a back-opening adjustment plate, and a lever fulcrum that are coaxially driven with the head-removing and cutting mechanism. The working height of the back-opening saw blade is adjusted in linkage with the angular displacement of the head-removing and cutting action. The electronic control system can perform program fine-tuning compensation on the linkage adjustment reference parameters based on the back-opening depth detection results collected by the vision monitoring unit and the actual rotation angle of the head-removing and cutting mechanism collected by the state perception unit, forming a dual depth adjustment closed loop of mechanical self-adaptation and software feedback correction.

8. The intelligent crayfish processing device as described in claim 2, characterized in that: The frame adopts a two-tiered layout. The lower tier is a closed transmission cavity with precision transmission components installed upside down, while the upper tier is an open processing area. The two are physically separated by a partition. The electrical control system is located at the top of the frame, and the detection ends of the visual monitoring unit and the status sensing unit are both located below the partition. The dual-channel conveying and clamping mechanism includes two independent synchronous belt conveyor tracks and two stepper motors. The two tracks are symmetrically arranged in the middle of the frame, and the two stepper motors are respectively mounted on the corresponding tracks and can drive the corresponding tracks to rotate, thus moving the shrimp clamping unit along the machine. The frame moves back and forth axially, and the two sets of tracks operate independently to coordinate the alternating operation of the two workstations; flexible rubber strips are symmetrically attached to both sides of the back-opening saw blade of the back-opening and gill-removing composite mechanism. The flexible rubber strips can rotate synchronously with the saw blade and intermittently press down on the shrimp claws of the shrimp body in a flexible contact manner; a protective cover is provided on the outside of the gill-removing component of the back-opening and gill-removing composite mechanism. A rinsing water pump is provided on the frame. The outlet of the rinsing water pump is connected to the rinsing hole and can rinse and clean the processed crayfish.

9. A processing method for crayfish based on the intelligent processing device according to any one of claims 1 to 8, characterized in that, Includes the following steps: S1. System initialization: The system is powered on and reset. The electronic control system initializes each processing channel, vision monitoring unit and status sensing unit. After completing the self-test, it enters the standby state. S2. Feeding and Scheduling: The operator places crayfish into the corresponding processing channel and triggers the start command. The electronic control system determines the channel status through the dual-station interlock scheduling logic. If there is no active channel, the processing process is started directly. If there is an active channel, the channel to be started is controlled to perform a pre-clamping action and enter the queue. S3. Processing steps: The active channel feeds the shrimp to the shrimp deveining station, head removal and cutting station, and back opening and gill removal station in a preset sequence, and the corresponding processing mechanism completes the processing actions of each step in sequence. S4. Multi-source fusion monitoring: Throughout the entire processing process, the visual monitoring unit collects shrimp images in real time according to the workstation rhythm and outputs visual detection signals, while the status perception unit collects the operating parameters of each execution component in real time and outputs status feedback signals. The electronic control system integrates the two types of signals to complete the real-time judgment of operating status and processing quality. S5. Abnormal Handling and Continuation: When the electrical control system determines that an abnormal state exists, it triggers the protection action of the corresponding processing channel and reports the abnormal information; when no abnormality is determined, the channel resets and unloads after completing all processes, and the queuing channel automatically continues to start the processing flow.

10. The intelligent processing method for crayfish as described in claim 9, characterized in that: In step S4, when the visual monitoring unit identifies the size difference of the crayfish in the current channel, the lower-level real-time control unit automatically matches the processing parameters corresponding to the size. The processing parameters include the clamping opening and closing angle, conveying speed, blade cutting stroke, and back opening depth linkage reference value. In step S5, a graded abnormality handling mechanism is adopted: when it is determined to be a hard fault type such as shrimp body falling off, workstation jamming, or motor stalling, all motion output of the corresponding channel is immediately stopped and an audible and visual alarm is triggered. At the same time, the upper-level computer displays the fault code and troubleshooting guidance. When it is determined to be a soft fault type such as processing accuracy deviation or movement angle offset, the abnormality log is recorded and the processing speed of the corresponding channel is reduced. When multiple shrimp bodies are processed and recovered to qualified, the processing speed is automatically restored to the standard processing speed.

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