A double-cylinder misaligned sorting roller automatic weighing device and control method

Abstract

The application provides a double-cylinder misalignment sorting roller automatic weighing device and a control method, relates to the technical field of mechanical automation detection and intelligent sorting, and the device comprises a conveying track, a double-cylinder blocking mechanism, a weighing and sorting mechanism and a control unit. The double-cylinder blocking mechanism is composed of a rear blocking cylinder and a front blocking cylinder which are sequentially arranged along the conveying direction, the effective distance L between the blocking ends of the two cylinders satisfies D < L < 2D, the diameter of the to-be-detected roller is D, a rigid single-piece separation constraint is formed, the control unit controls the two cylinders to alternately stretch and shrink so that a single roller falls into a scale pan, a weighing sensor collects a falling pan impact signal, the control unit calculates the mass and compares the mass with a preset tolerance band, and then drives a turnover driving element to make the scale pan tilt and unload. The application realizes anti-stacking through physical distance constraint, shortens the detection period by cooperating with a dynamic weighing algorithm, is suitable for high-precision online full-detection sorting scenes, and takes into account the weighing precision and the production line beat.

Description

Technical Field

[0001] This invention relates to the field of mechanical automation detection and intelligent sorting technology, and more specifically, to an automated roller weighing device and control method for double-cylinder staggered sorting. Background Technology

[0002] In the manufacturing process of continuously variable transmissions (CVTs) for motorcycles and various precision mechanical transmission systems, transmission rollers (such as counterweight balls, cylindrical sleeve rollers, etc.) are core transmission components that control the gear ratio and dynamic balance, and their individual component quality consistency is subject to extremely stringent requirements. To ensure assembly quality and smooth operation, all rollers typically undergo precise online weighing and sorting before leaving the factory.

[0003] In automated continuous weighing operations, ensuring that the rollers to be tested fall into the weighing station in an orderly manner, individually and independently, is a prerequisite for achieving high-precision weighing and accurate sorting. However, existing roller weighing and sorting equipment still has significant technical deficiencies in the unloading and sorting stages: During material conveying, rollers are fed by vibration and move forward along the conveyor track. The sliding distance between each roller at the end of the track is highly random, and adjacent rollers are prone to sticking together or sliding continuously. To achieve single-piece release, existing technologies generally use a soft control method of "sensor detection combined with control delay" to control the cylinder blocking. However, due to the inherent physical lag between the photoelectric sensor's triggering, the control system's calculation, and the pneumatic actuator's response, in high-frequency continuous operation of the production line, relying solely on software timing delay is prone to untimely interception or blocking failure, resulting in multiple / double materials sliding onto the weighing pan simultaneously, causing weighing misjudgments and sorting errors.

[0004] Furthermore, in traditional material distribution and blocking mechanisms, the arrangement and spacing of cylinders usually lack a precise constraint relationship with the geometric dimensions of the rollers. This makes it impossible to form a physical waiting area that can accommodate only a single roller at the mechanical hardware level, and it is difficult to form a reliable rigid blockage of subsequent rollers in geometric space.

[0005] In summary, existing roller weighing equipment, lacking a rigid physical anti-double-material structure matching the roller's outer diameter, is prone to material stacking and double-material slippage during high-speed continuous operation, severely impacting the accuracy of weighing and sorting and the operational stability of the production line. Therefore, there is an urgent need to develop an automated roller weighing device with a rigid, single-piece separation structure that reliably prevents double-material slippage onto the weighing pan. Summary of the Invention

[0006] The technical problem to be solved by the present invention is that the lack of a rigid physical anti-double material structure in the existing roller automated weighing process leads to the technical contradiction of easy stacking and double material slippage misjudgment during high-frequency conveying. In order to overcome the above defects of the prior art, the present invention provides a roller automated weighing device and control method with double cylinder misalignment sorting.

[0007] This invention provides an automated weighing device for rollers with dual-cylinder staggered sorting, used for weighing and sorting rollers with an outer diameter of D, comprising: A conveyor track is used to convey the roller to be tested along the conveying direction; A dual-cylinder blocking mechanism includes a rear blocking cylinder and a front blocking cylinder sequentially arranged at the end of the conveying track along the conveying direction. The effective distance between the blocking end of the front blocking cylinder and the blocking end of the rear blocking cylinder is L, and satisfies D. <L<2D; The weighing and sorting mechanism includes a weighing pan disposed below the end of the conveying track, a weighing sensor connected to the weighing pan, and a tilting drive for driving the weighing pan to tilt. The control unit is electrically connected to the front blocking cylinder, the rear blocking cylinder, the weighing sensor, and the tilting drive. It is used to control the rear blocking cylinder and the front blocking cylinder to extend and retract alternately so that a single roller to be tested falls into the weighing pan. The control unit determines the mass of the roller to be tested based on the weighing signal collected by the weighing sensor, and drives the tilting drive to tilt the weighing pan to unload the material based on the determination result.

[0008] Compared with existing technologies, the automated roller weighing device with dual-cylinder staggered sorting proposed in this application has the following advantages: By limiting the effective distance between the front blocking cylinder and the rear blocking cylinder to a physical range between the outer diameter of a single roller and the sum of the dimensions of both rollers, and through the alternating extension and retraction of the two cylinders driven by the control unit, a single-piece waiting area can be forcibly formed on the material conveying path, significantly reducing the risk of both materials slipping onto the weighing pan simultaneously; at the same time, the device, combined with a weighing sensor, acquires the roller mass signal in real time and drives the flipping sorting mechanism to complete the unloading, so that the entire weighing and sorting process has the basis of single-piece conveying at the physical structure level, which is conducive to improving the continuity and accuracy of weighing operations in high-frequency continuous conveying processes.

[0009] In one possible implementation, the weighing and sorting mechanism further includes a sorting channel disposed below the weighing pan, the sorting channel including a qualified side slide groove disposed on the right side of the weighing pan and an unqualified side slide groove disposed on the left side of the weighing pan, and the flipping drive is a flipping cylinder disposed at the bottom of the weighing pan, used to controllably drive the weighing pan to tilt to the left or right.

[0010] Compared with existing technologies, the horizontally arranged weighing pan is tilted towards the qualified or unqualified side slide by a flip cylinder, resulting in a clear classification path, direct sorting action response, and simple structure.

[0011] In one possible implementation, an automatic feeding system is also included, comprising a disc-type vibratory feeder connected to a conveying track and a vibration controller communicatively connected to a control unit; a photoelectric sensor is provided on the side of the conveying track for detecting the material level at the end of the conveying track, and the vibration controller adjusts the vibration frequency according to the material level.

[0012] Compared with existing technologies, using photoelectric sensors to detect material level and using a vibration controller for closed-loop adjustment helps maintain adaptive coordination between upstream feeding and downstream weighing cycles, reducing operational interruptions caused by accumulation or gaps.

[0013] In one possible implementation, a slide rail is also included, which is installed on the side of the conveying track. The front blocking cylinder and the rear blocking cylinder are slidably mounted on the slide rail, and the slide rail is provided with a locking mechanism for locking the relative positions of the front blocking cylinder and the rear blocking cylinder to adjust the effective distance L.

[0014] Compared with existing technologies, the installation position of the blocking cylinder can be flexibly adjusted and locked according to the outer diameter of the roller by means of a sliding rail and locking mechanism, which helps to improve the compatibility of the device with production tasks of rollers of different sizes.

[0015] In one possible implementation, pneumatic speed control valves are installed on the air passage interfaces of both the front and rear blocking cylinders to adjust the impact speed when the blocking end extends.

[0016] Compared with existing technologies, pneumatic speed control valves can adjust the execution speed when the cylinder blocking end extends or retracts, which helps to reduce the impact vibration generated by mechanical action, thereby improving the environmental stability of the weighing process.

[0017] In one possible implementation, an inclined guide swashplate is provided between the end of the conveying track and the weighing pan to guide the roller to be tested to smoothly transition into the weighing pan.

[0018] Compared with existing technologies, the inclined guide swashplate provides a buffer path for the rollers to transition from the end of the conveyor track to the weighing pan, which helps to reduce the skew and bounce of the rollers when they fall onto the pan and improves the smoothness of the material dropping process.

[0019] In one possible implementation, the outer cover of the weighing and sorting mechanism is provided with a transparent windproof protective cover, which encloses the weighing pan and weighing sensor inside to isolate the weighing process from interference from external airflow.

[0020] Compared with existing technologies, the transparent windproof protective cover encloses the weighing pan and weighing sensor in the internal space, which can isolate the interference of environmental airflow changes on weak weighing signals to a certain extent, and helps to improve the accuracy of data acquisition.

[0021] Another technical solution of the present invention is to provide an automated weighing control method for rollers in a dual-cylinder staggered sorting system, comprising the following steps: Step S1: Control the rear blocking cylinder to remain extended to intercept the rear roller, and then control the front blocking cylinder to retract, so that the only roller to be tested located between the front blocking cylinder and the rear blocking cylinder slides down to the weighing pan. Step S2: Collect the weighing signal output by the weighing sensor during the process of the roller to be tested falling into the weighing pan, and calculate the mass of the roller to be tested; Step S3: Compare the calculated mass with the preset tolerance zone to obtain the comparison result; Step S4: Based on the comparison results, drive the tilting drive to tilt the weighing pan to complete the unloading, and then control the weighing pan to return to a horizontal state; Step S5: Control the front blocking cylinder to extend to block the outlet of the conveying track, then control the rear blocking cylinder to briefly retract to allow the next test roller to enter between the front blocking cylinder and the rear blocking cylinder, then control the rear blocking cylinder to extend again and return to step S1.

[0022] Compared with existing technologies, this control method provides a logically rigorous operating sequence for automated roller weighing and sorting. Through alternating steps of the rear blocking cylinder maintaining interception, the front blocking cylinder cooperating to release, and the subsequent front cylinder blocking, the rear cylinder briefly retracting to fill the gap and then re-extending, it can effectively ensure that each roller enters the weighing and judgment stage in an orderly and independent manner. At the same time, by timely collecting weighing signals and calculating the mass, it can quickly produce judgment results and drive the sorting mechanism to achieve targeted unloading. This process achieves a smooth connection between mechanical action and signal processing, which is conducive to improving the flow efficiency of automated sorting operations.

[0023] In one possible implementation, in step S2, calculating the mass of the roller to be tested specifically includes: capturing the drop impact waveform collected by the weighing sensor, fitting the intermediate trend line of the drop impact waveform using an algorithm, and calculating the steady-state mass value after the waveform oscillation disappears based on the intermediate trend line.

[0024] Compared with existing technologies, by capturing the impact waveform after the roller falls onto the plate and fitting its intermediate trend line to estimate the steady-state quality after the oscillation disappears, the dependence on waiting for the roller to be completely still is reduced, which is beneficial to shorten the detection and judgment time of a single roller while maintaining a certain level of accuracy.

[0025] In one possible implementation, a recipe initialization step is included before step S1: Select the target parameter formula corresponding to the specifications of the roller to be tested. The control unit automatically loads the target weight reference value and the upper and lower limits of the tolerance zone in the parameter formula, and adjusts the effective distance L between the front blocking cylinder and the rear blocking cylinder according to the outer diameter D of the roller to be tested.

[0026] Compared with existing technologies, by pre-selecting the target parameter formula and automatically loading the corresponding benchmark value and tolerance threshold, and then adjusting the effective cylinder spacing according to the outer diameter of the roller, the debugging cycle when changing production of multi-specification rollers can be effectively shortened, and the cumbersomeness of manually switching mechanical and software parameters can be reduced. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the first state of the overall structure of the automated roller weighing device with dual-cylinder staggered sorting provided in an embodiment of the present invention. Figure 2 This is a schematic diagram of the second state of the overall structure of the automated roller weighing device with dual-cylinder staggered sorting provided in an embodiment of the present invention. Figure 3 This is a schematic diagram of the conveyor track and automatic feeding system in the roller automated weighing device for double-cylinder staggered sorting provided in an embodiment of the present invention. Figure 4 A flowchart of the control method provided in an embodiment of the present invention.

[0028] Explanation of reference numerals in the attached figures: 1. The roller to be tested; 2. Conveying track; 21. Photoelectric sensor; 22. Slide rail; 3. Dual-cylinder blocking mechanism; 31. Front blocking cylinder; 32. Rear blocking cylinder; 4. Weighing and sorting mechanism; 41. Weighing pan; 411. Guide slant plate; 42. Weighing sensor; 43. Tilting drive; 44. Sorting channel; 441. Qualified side slide; 442. Unqualified side slide; 5. Control unit; 6. Automatic feeding system; 61. Disc vibratory feeder; 62. Vibration controller. Detailed Implementation

[0029] First, those skilled in the art should understand that these embodiments are merely used to explain the technical principles of the embodiments of this application and are not intended to limit the scope of protection of the embodiments of this application. Those skilled in the art can make adjustments as needed to adapt to specific application scenarios.

[0030] In the description of the embodiments of this application, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this application according to the specific circumstances.

[0031] In the embodiments of this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0032] The present application will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0033] Example 1 See Figures 1-3 This application discloses an automated weighing device for rollers with dual-cylinder staggered sorting. This device is mainly used for automated online weighing and mass sorting of rollers 1 with an outer diameter of D. Structurally, the device mainly includes: a conveyor track 2 for carrying and guiding the rollers 1 forward; a dual-cylinder blocking mechanism 3 located at the end of the conveyor track 2 to achieve single-piece separation; a weighing and sorting mechanism 4 located below the end of the conveyor track 2 to achieve weighing and unloading; and a control unit 5 serving as the core decision-making and control unit.

[0034] Specifically, the conveying track 2 is a straight chute, with a chute width slightly larger than the outer diameter D of the roller 1 to be tested, and a chute depth greater than the height of the roller 1 to be tested, to ensure that the roller 1 to be tested is stably arranged in a single row and rolls / slides forward along the track extension direction (i.e., the conveying direction) under the action of gravity. The conveying track 2 can be made of stainless steel or wear-resistant engineering plastic to reduce friction loss and material contamination risk during long-term operation. At the end of the conveying track 2, that is, the transition section where the roller 1 to be tested is about to leave the track and enter the weighing area, guide guards can be provided on both sides of the track to prevent the roller 1 to be tested from lateral deviation or accidental jump out before entering the blocking area.

[0035] Further, see Figure 1 and Figure 2, the double-cylinder blocking mechanism 3 comprises a rear blocking cylinder 32 and a front blocking cylinder 31 sequentially arranged at the end of the conveying track 2 along the conveying direction. The terms "front" and "rear" herein are defined relative to the conveying direction, that is, the rollers 1 to be tested pass through the position of the rear blocking cylinder 32 first, then pass through the position of the front blocking cylinder 31, and finally slide out from the end of the conveying track 2. Both the front blocking cylinder 31 and the rear blocking cylinder 32 are single-acting or double-acting linear cylinders, and the blocking end (i.e., the end of the piston rod) thereof is fitted with a stopper or a stop rod extending perpendicular to the axial direction of the conveying track 2. When the blocking end extends out, the stopper spans above the groove surface of the conveying track 2, thereby physically blocking the rolling path of the roller 1 to be tested; when the blocking end retracts, the stopper retreats to the side of the track, allowing the roller 1 to be tested to pass freely.

[0036] The effective spacing between the blocking end of the front blocking cylinder 31 and the blocking end of the rear blocking cylinder 32 is L. The "effective spacing" herein refers to the distance measured along the conveying direction between the rear side surface of the stopper of the front blocking cylinder 31 and the front side surface of the stopper of the rear blocking cylinder 32, which defines the length of the physical space where two rollers 1 to be tested can stay simultaneously.

[0037] In this embodiment, the effective spacing L is strictly limited to satisfy D<L<2D. The setting of this geometric constraint has profound physical significance: when L>D, it ensures that at least one roller can be completely accommodated between the two blocking ends, forming an independent waiting area; when L<2D, it physically eliminates the possibility that two rollers are completely accommodated in this area at the same time. This rigid dimensional constraint is the core structural basis for realizing the physical anti-stacking function of the present invention, which is different from the soft anti-stacking solution that simply relies on sensor delay control.

[0038] As a preferred embodiment, in order to realize rapid adjustment of the effective spacing L to adapt to rollers 1 to be tested with different outer diameters D, a slide rail 22 is further installed on the side of the conveying track 2. The front blocking cylinder 31 and the rear blocking cylinder 32 are slidably installed on the slide rail 22, and a locking mechanism is further provided thereon. An operator or an automatic actuator can push the front blocking cylinder 31 and / or the rear blocking cylinder 32 along the slide rail 22 to the target position according to the current batch specification of the rollers 1 to be tested, and then lock the position via the locking mechanism. For example, for a roller with an outer diameter D=10mm, the effective spacing L can be adjusted to 15mm; for a roller with an outer diameter D=15mm, L can be adjusted to 22mm. The adjustment process can be completed manually during production changeover, or can be automatically adjusted by an electric adjustment mechanism communicatively connected to the control unit 5.

[0039] Wherein, the locking mechanism can be a jackscrew, a quick clamp or an eccentric wheel locking device; the automatic actuator can be a screw module driven by a servo motor.

[0040] In terms of pneumatic control, pneumatic speed control valves are installed on the air passage interfaces of both the front blocking cylinder 31 and the rear blocking cylinder 32. These valves effectively control the speed of the blocking end's extension and retraction by adjusting the flow rate of compressed air entering or exiting the cylinder chamber. During actual commissioning, the extension speed can be adjusted to a moderate level, for example, with the piston rod linear speed not exceeding 50 mm / s, to avoid damage to the surface of the test roller 1 caused by high-speed impact of the blocking block or excessive impact causing the roller to jump. Simultaneously, the retraction speed can be adjusted to a faster level, for example, not less than 80 mm / s, to shorten the action cycle and improve the sorting pace. This speed control strategy helps to achieve a balance between protecting the surface quality of the test roller 1 and ensuring operational efficiency.

[0041] Among them, the pneumatic speed control valve can be a throttle valve or an exhaust throttle valve.

[0042] See Figure 1 and Figure 2 The weighing and sorting mechanism 4 is located below the end of the conveying track 2, and mainly includes a weighing pan 41, a weighing sensor 42, and a flipping drive 43.

[0043] The weighing pan 41 is a horizontally arranged circular or rectangular tray with a slightly concave arc or anti-slip texture on its bearing surface. It is used to receive the roller 1 to be tested that slides down from the end of the conveyor track 2 and to prevent it from rolling unnecessarily on the weighing pan 41.

[0044] The load cell 42 is preferably a high-precision resistance strain gauge load cell, such as a single-point sensor with a range of 0g to 200g and an accuracy class of C3 or higher. One end of its elastic body is fixedly mounted on the frame or base, and the other end is connected to the center of the bottom of the weighing pan 41. When the roller 1 to be measured falls onto the weighing pan 41, its gravity is transmitted through the weighing pan 41 to the elastic body of the load cell 42, causing it to produce micro-strain, which is then converted into an electrical signal output proportional to its mass.

[0045] The tilting drive 43 is used to drive the weighing pan 41 to tilt around a horizontal axis to achieve unloading and sorting. In one specific embodiment, the tilting drive 43 is a tilting cylinder located at the bottom of the weighing pan 41. The cylinder body is mounted on a fixed frame via a hinge support, and the end of its piston rod is hinged to one side of the bottom of the weighing pan 41 via a linkage mechanism or directly. When the piston rod extends or retracts, it pushes the weighing pan 41 to tilt to the left or right around a support shaft on the other side of its bottom.

[0046] Preferably, a sorting channel 44 is provided below the weighing pan 41. The sorting channel 44 includes a qualified side chute 441 located on the right side of the weighing pan 41 and a defective side chute 442 located on the left side of the weighing pan 41. When the control unit 5 determines that the quality of the roller 1 to be tested is qualified, it drives the tilting cylinder to tilt the weighing pan 41 to the right, for example, at an angle of 15° to 30°, and the roller slides into the qualified side chute 441 along the inclined surface; if it is determined to be defective, it drives the tilting cylinder to tilt the weighing pan 41 to the left, and the roller slides into the defective side chute 442. The outlet ends of the qualified side chute 441 and the defective side chute 442 can be connected to the corresponding finished product collection box or defective product isolation box, respectively.

[0047] In practical applications, the control unit 5 is communicatively connected to a human-machine interface, such as a touch-screen industrial display screen located at the front of the equipment. The local memory electrically connected to the control unit 5 stores multiple sets of parameter formulas for different specifications of the rollers 1 to be tested. Each set of parameter formulas includes the target basis weight, tolerance band upper and lower limits, and basic control cycle for that specific specification of roller 1. Operators can intuitively select formulas, access parameters, and switch between them with a single click through the human-machine interface. Based on the received formula instructions, the control unit 5 automatically loads the corresponding control parameters and sends them to each actuator, thereby achieving efficient and adaptive production changes for multiple specifications of rollers 1 to be tested.

[0048] The basic control cycle includes the basic timing interval for the alternating extension and retraction of the cylinders and the basic sampling waiting time.

[0049] To enhance the anti-interference capability of the weighing process, a transparent windproof protective cover is installed on the outer side of the weighing and sorting mechanism 4. This cover, made of transparent plexiglass or polycarbonate sheet, completely encloses the weighing pan 41 and the load cell 42, forming a relatively enclosed space. An operating window with a soft, sealed curtain can be provided on the cover for easy daily maintenance and cleaning. This cover effectively isolates interference from the weak output signal of the load cell 42 caused by turbulent airflow from the workshop's air conditioning, personnel movement, or equipment operation, thereby significantly improving the signal-to-noise ratio and repeatability of the data acquisition. In applications requiring extremely high accuracy, temperature and humidity sensors can be added inside the cover for real-time monitoring and compensation of environmental parameters.

[0050] See you again Figure 1 and Figure 2An inclined guide swashplate 411 is provided between the end of the conveying track 2 and the weighing pan 41. The guide swashplate 411 is a thin metal or ceramic plate with a smooth upper surface. Its high end connects to the end outlet of the conveying track 2, and its low end connects to the edge of the weighing pan 41. The inclination angle of the guide swashplate 411 is preferably 30° to 60°. After the roller 1 to be tested is released from the front blocking cylinder 31, it first falls on the upper end of the guide swashplate 411, and then rolls or slides down the inclined surface under the action of gravity, finally falling smoothly into the weighing pan 41 from the low end. This intermediate transition structure avoids the excessive impact kinetic energy generated by the roller 1 falling vertically from the end of the conveying track 2 to the weighing pan 41, effectively reducing the oscillation amplitude of the weighing pan 41, which is beneficial for the subsequent weighing algorithm to extract a stable mass signal more quickly.

[0051] See Figure 3 The automated weighing device for rollers with dual-cylinder staggered sorting provided in this embodiment preferably includes an automatic feeding system 6 for continuously and stably supplying the rollers 1 to be tested. The automatic feeding system 6 includes a disc-type vibratory feeder 61 connected to the inlet end of the conveyor track 2 and a vibration controller 62 communicatively connected to the control unit 5. The disc-type vibratory feeder 61 has a spirally ascending feeding track inside. Through the high-frequency vibration of the bottom electromagnet, the randomly stacked rollers 1 to be tested are arranged into an orderly single column and fed into the conveyor track 2 one by one. The vibration controller 62 is used to adjust the operating frequency and amplitude of the vibratory feeder.

[0052] A photoelectric sensor 21 is provided on the side of the conveying track 2 (preferably upstream of the rear blocking cylinder 32) to detect the material level status of the conveying track 2, that is, to detect whether there is an accumulation or gap of the roller 1 to be tested at this position. The photoelectric sensor 21 can be a diffuse reflection type or a through-beam type photoelectric switch.

[0053] The photoelectric sensor 21 feeds back the detection signal to the control unit 5 in real time. The control unit 5 uses this signal to determine if there is sufficient material coming from upstream: when the photoelectric sensor 21 is blocked, it indicates that there is continuous material on the conveyor track 2, maintaining the current output of the vibration controller 62; when the photoelectric sensor 21 is not blocked, it indicates that there is a shortage of material on the conveyor track 2. If this exceeds a predetermined time (e.g., 0.5 seconds), the control unit 5 sends a speed-up command to the vibration controller 62 to increase the vibration frequency and accelerate the material supply; when the photoelectric sensor 21 is blocked for a long time and the front blocking cylinder 31 frequently intercepts, it indicates that there is severe material accumulation at the end of the conveyor track 2, and a speed-down command is sent to the vibration controller 62 to reduce the material supply rate and prevent blockage. Through this closed-loop control strategy, adaptive matching between upstream material supply and downstream weighing cycle time is achieved.

[0054] In this embodiment, the control unit 5 integrates an industrial Ethernet communication interface. Through this industrial Ethernet interface, the control unit 5 can not only monitor the real-time sorting cycle of the weighing and sorting mechanism 4, but also obtain the material level status fed back by the photoelectric sensor 21 installed on the side of the conveyor track 2. The control unit 5 has a built-in closed-loop control algorithm: when the photoelectric sensor 21 detects that there is material accumulation and blockage at the end of the conveyor track 2, the control unit 5 immediately sends a deceleration / reduction command to the upstream vibration controller 62 via the industrial Ethernet to reduce the vibration frequency of the disc vibrating plate 61; when it detects that the material level on the conveyor track 2 is empty or lacking material, it sends an acceleration command to the upstream vibration controller 62 to increase the feeding rate, ensuring that the material receiving cycle and the weighing and sorting cycle are adaptively coordinated in real time.

[0055] Meanwhile, the control unit 5 will package and upload the absolute mass data, pass / fail judgment results and timestamp of each roller 1 to be tested calculated by each weighing in real time to the MES system or industrial cloud platform in the workshop via the industrial Ethernet interface, providing full data support for the quality traceability, statistical process control analysis and production line capacity optimization of the production line.

[0056] In summary, the working principle of the device in the above embodiment is as follows: through the alternating extension and retraction of the front blocking cylinder 31 and the rear blocking cylinder 32 in the dual-cylinder blocking mechanism 3 at a specific distance L, in conjunction with the guide swashplate 411 at the end of the conveying track 2, the rollers 1 to be tested are smoothly fed one by one onto the weighing pan 41 of the weighing and sorting mechanism 4; the weighing pan 41 transmits the weight of the rollers to the weighing sensor 42, and the sensor outputs an electrical signal to the control unit 5; the control unit 5 uses a dynamic weighing algorithm to quickly calculate the steady-state mass value, compares it with the preset tolerance zone, and outputs a sorting command; the flipping drive 43 drives the weighing pan 41 to tilt to the corresponding side according to the command, so that the rollers slide into the qualified side slide groove 441 or the unqualified side slide groove 442; at the same time, the control unit 5 controls the front blocking cylinder 31 and the rear blocking cylinder 32 to work together to complete the preparation of the next roller, and so on, to achieve high-speed and high-precision automated sorting.

[0057] Example 2 See Figures 1-4 As shown, this application also provides an automated weighing control method for rollers using a dual-cylinder staggered sorting system. This method can be applied to the apparatus described in the above embodiments. The method will be described in detail below with reference to specific application scenarios.

[0058] At the start of the equipment, the formula initialization step is performed first. The operator selects the specification and model of the roller 1 to be tested through the human-machine interface of the control unit 5, or the product parameters are automatically issued by the production line management system. The control unit 5 automatically loads the corresponding target parameter formula according to the selected specification. This formula includes at least the target basis weight value (e.g., 15.000g), the upper limit threshold of the tolerance zone (e.g., +0.050g), and the lower limit threshold of the tolerance zone (e.g., -0.050g). At the same time, the control unit 5 generates the target position commands for the front blocking cylinder 31 and the rear blocking cylinder 32 based on the outer diameter D value of the roller 1 to be tested recorded in the formula, combined with the preset spacing calculation formula or by querying the internal parameter mapping table. If the device is equipped with an electric adjustment mechanism, the control unit 5 automatically drives the slider to move along the slide rail 22 to the target position and locks it; if it is manually adjusted, the control unit 5 displays the suggested effective spacing L value on the screen for the operator to refer to and adjust. After the formula initialization is completed, the automatic feeding system 6 is started, and the roller 1 to be tested begins to be conveyed forward along the conveyor track 2.

[0059] The human-computer interaction interface can be a touchscreen display.

[0060] When the rollers to be tested 1 arrive successively at the area of ​​the double-cylinder blocking mechanism 3, the cyclic weighing and sorting process begins. This process includes the following steps: Step S1: The control unit 5 first ensures that the rear blocking cylinder 32 remains extended, with its blocking end spanning across the conveying track 2, thereby intercepting all subsequent test rollers 1 conveyed from upstream.

[0061] At this time, the front blocking cylinder 31 is also in the extended state, forming a blockage. Within the effective distance L between the front blocking cylinder 31 and the rear blocking cylinder 32, there is one and only one roller 1 to be tested, and the rear roller 1 to be tested is blocked in front by the rear blocking cylinder 32.

[0062] Subsequently, the control unit 5 sends a command to retract the blocking end of the front blocking cylinder 31. Since the rear blocking cylinder 32 remains extended, the rear roller cannot advance. Therefore, only the roller 1 to be tested, located between the two cylinders, obtains a release path. Under the action of gravity, it slides out of the end of the conveying track 2, is buffered by the guide swashplate 411, and falls into the weighing pan 41. This achieves the precise release of a single roller 1 to be tested.

[0063] Step S2: During the entire dynamic process of the roller 1 to be tested falling into the weighing pan 41, the load cell 42 continuously outputs a weighing signal that reflects the instantaneous force value of the weighing pan 41, i.e., the impact waveform of the falling pan.

[0064] Control unit 5 acquires the analog signal at a high sampling frequency and converts it into a digital quantity. In order to quickly obtain an accurate mass value without waiting for the roller 1 under test to be physically completely stationary, control unit 5 executes a dynamic weighing algorithm: specifically, it includes capturing the impact waveform data from the moment the roller 1 under test contacts the weighing pan 41 until approximately 200ms to 500ms thereafter; fitting the intermediate trend line of the waveform using a pre-stored algorithm model (such as least squares fitting, recursive least squares RLS filtering, Kalman filtering, or a waveform feature recognition model trained based on a neural network); this intermediate trend line reflects the trend of the change in the center of mass value during the vibration decay process; finally, based on the asymptotic value of this trend line or through extrapolation, the steady-state mass value after the waveform oscillation disappears is obtained.

[0065] Specifically, at the instant the roller 1 to be tested falls into the weighing pan 41 (denoted as time t0), an impulse is applied to the weighing pan 41, causing the load cell 42 to output a typical underdamped second-order decaying oscillation curve S(t). If the oscillation is allowed to decay naturally and completely stop, it usually takes 400ms to 600ms.

[0066] To eliminate the constraint of "complete standstill waiting" on the production cycle, this embodiment adopts a fast quality prediction algorithm based on underdamped impact waveform fitting in step S2. The specific calculation process is as follows: Control unit 5 captures the impact waveform data segment of the roller 1 falling onto the weighing pan 41 in real time at a high sampling rate (e.g., 2000Hz), within the first 50ms to 150ms, and includes at least 1.5 to 2 complete oscillation cycles. According to the physical mechanics model, the response waveform of the weighing system can be expressed as:

[0067]

[0068] in, Let g be the actual mass value to be determined after the waveform oscillation disappears, g be the acceleration due to gravity, and A be the initial impact amplitude. For the system damping ratio, The natural angular frequency, The damping angular frequency, For the initial phase, For high-frequency noise, t is the time variable after the roller 1 to be tested falls onto the weighing pan 41.

[0069] Control unit 5 utilizes a least-squares fitting algorithm or an envelope filtering fitting algorithm to quickly fit the upper and lower envelopes and the intermediate trend line of the underdamped impact waveform, i.e., the central convergence average of the waveform oscillation. By solving the limiting convergence asymptote of the fitted curve, the steady-state mass value after the waveform oscillation completely disappears can be accurately calculated directly within 100ms. This digital algorithm fitting and estimation technology, while ensuring a weighing accuracy of ±0.01g, significantly reduces the weighing acquisition time for a single roller from 500ms in the traditional scheme to less than 100ms, thus significantly shortening the single-piece inspection cycle.

[0070] Step S3: The control unit 5 compares the steady-state mass value calculated in step S2 with the target weight reference value and the upper and lower tolerance thresholds loaded in step S1 to generate a comparison result. If the mass value falls within the closed interval of [reference value - lower threshold, reference value + upper threshold], it is determined to be a qualified product; otherwise, it is determined to be a non-qualified product, including both ultra-light and ultra-heavy cases.

[0071] Step S4: Based on the determination result of step S3, the control unit 5 sends a corresponding drive signal to the flip drive 43.

[0072] If the product is determined to be qualified, the piston rod of the control cylinder extends or retracts, driving the weighing pan 41 to tilt to the right, for example, at a 25° angle, so that the roller 1 to be tested slides into the qualified side groove 441 under the action of gravity. If the product is determined to be unqualified, the weighing pan 41 is driven to tilt to the left, so that the roller 1 to be tested slides into the unqualified side groove 442.

[0073] To ensure that the rollers slide completely off, the flipping action can be maintained for a certain period of time, such as 0.2 to 0.3 seconds. Then, the flipping cylinder is controlled to reverse the action, so that the weighing pan 41 is reset to a horizontal state, ready to receive the next roller 1 to be tested.

[0074] Step S5: At the same time as or shortly after the weighing pan 41 flips over to unload the material (no later than before the weighing pan 41 has been reset), the control unit 5 sends a command to make the front blocking cylinder 31 extend again to re-seal the outlet end of the conveying track 2.

[0075] Then, the control unit 5 briefly retracts the rear blocking cylinder 32, for example, for 0.2 to 0.4 seconds, to open a path for the next test roller 1 that was blocked behind it. Since the front blocking cylinder 31 has been extended, the next roller can only advance to the stop of the front blocking cylinder 31 and be stopped. At this time, the test roller 1 is exactly within the effective distance L between the front blocking cylinder 31 and the rear blocking cylinder 32.

[0076] Subsequently, control unit 5 again controls the rear blocking cylinder 32 to extend, intercepting the subsequent test roller 1. At this point, the dual-cylinder blocking mechanism 3 has returned to its initial state, and a new test roller 1 has been stored between the two cylinders. The control flow returns to step S1 to begin the next cycle.

[0077] To eliminate weighing drift caused by temperature fluctuations, mechanical stress release, or trace amounts of oil adhering to the surface of the weighing pan 41 during long-term continuous operation of the equipment, this control method also includes a zero-point calibration step before step S1 or after each preset number of weighing cycles: When the weighing and sorting mechanism 4 completes the unloading of the previous roller and the tilting drive 43 drives the weighing pan 41 to return to a horizontal and unloaded state, the control unit 5 acquires the zero-point voltage / digital signal output by the load cell 42 in real time. The control unit 5 compares this zero-point output signal with the initial absolute zero point; if there is a slight deviation within the allowable zero-point drift range, the control unit 5 automatically performs a zeroing or tare calibration operation, resetting the current unloaded signal to a new software zero-point reference.

[0078] The dynamic zero-point calibration process is completed discreetly between two weighing cycles, without the need for manual intervention to stop the machine, ensuring measurement accuracy and long-term stability in continuous high-frequency weighing scenarios.

[0079] Through the above-described cycle, this invention achieves continuous, efficient, and high-precision automated weighing and sorting of the rollers to be tested. Throughout the process, the physical constraint of the effective spacing L significantly reduces the risk of both materials slipping simultaneously, while the dynamic weighing algorithm breaks through the time bottleneck of traditional "static waiting." The synergistic effect of the two enables the device to achieve a processing cycle of over 2400 pieces / hour while maintaining a weighing accuracy of ±0.01g.

[0080] In some alternative embodiments, the dynamic weighing algorithm in the above control method can select different fitting strategies according to the different specifications of the rollers. For example, for roller 1 with a small mass (e.g., less than 5g), its impact waveform decays quickly when dropped onto the plate, so a simple first-order low-pass filter combined with trend extrapolation can be used; for roller 1 with a large mass (e.g., more than 30g), its oscillation frequency is low, so an adaptive parameter estimation method based on the AR model can be used. The parameter formula of the control unit 5 can include an algorithm type flag and filter coefficients for each specification to achieve the best match "tailored to the specific part".

[0081] The control method provided by this invention also includes abnormal cycle time self-diagnosis and automatic recovery steps. During equipment operation, the control unit 5 performs real-time logic diagnosis on the feedback signals of each cylinder position detection sensor, such as the magnetic switches installed on the front blocking cylinder 31, the rear blocking cylinder 32, and the flipping drive 43, as well as the weighing signal: if the control unit 5 detects that the cylinder position detection sensor does not provide a feedback signal within a predetermined time, it indicates that the cylinder action is blocked, or after a preset basic sampling waiting time, the signal collected by the weighing sensor 42 continues to fluctuate violently after reaching the maximum warning time, indicating that the roller 1 to be tested is stuck or two materials are squeezed between the blocking end and the weighing pan 41 at the outlet of the conveying track 2.

[0082] Control unit 5 immediately triggers the material jamming and unblocking recovery procedure: Control unit 5 instructs the front blocking cylinder 31 and the rear blocking cylinder 32 to perform rapid alternating extension and retraction actions, for example, to extend and retract 2 to 3 times with high-frequency continuous pneumatic impact, using the physical and mechanical vibration of the cylinder blocking end to forcibly unblock and disperse the roller 1 to be tested that is stuck at the end of the conveying track 2.

[0083] After performing the unblocking action, the control unit 5 checks the sensor status again. If the jam is successfully cleared and the signal returns to normal, the equipment automatically resumes the normal weighing cycle; if it still does not return to normal after performing the unblocking action, it indicates a serious mechanical jam or no-material fault. The control unit 5 immediately sends a stop command to the vibration controller 62 to stop the upstream disc vibrating plate 61 from feeding material, and at the same time triggers the audible and visual alarm set on the frame, and pushes the specific fault code and fault location prompt to the human-machine interface, waiting for manual troubleshooting intervention.

[0084] It should be understood that the above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention, such as replacing the cylinder with an electric cylinder or a hydraulic cylinder, replacing the V-shaped track with a rectangular groove track, or replacing the tilting cylinder with a rotary motor or a linear push rod, should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

[0085] In the description of the embodiments of this application, it should be noted that the terms "inner" and "outer", etc., which indicate the direction or positional relationship, are based on the direction or positional relationship shown in the drawings. This is only for the convenience of description and does not indicate or imply that the device or component must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this application.

[0086] In the description of this application, the references to terms such as "an embodiment," "some embodiments," "in this embodiment," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0087] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. An automated weighing device for rollers with dual-cylinder staggered sorting, used for weighing and sorting rollers (1) with an outer diameter of D, characterized in that, include: A conveying track (2) is used to convey the roller (1) to be tested along the conveying direction. The dual-cylinder blocking mechanism (3) includes a rear blocking cylinder (32) and a front blocking cylinder (31) sequentially arranged at the end of the conveying track (2) along the conveying direction. The effective distance between the blocking end of the front blocking cylinder (31) and the blocking end of the rear blocking cylinder (32) is L, and satisfies D. <L<2D; The weighing and sorting mechanism (4) includes a weighing pan (41) located below the end of the conveying track (2), a weighing sensor (42) connected to the weighing pan (41), and a tilting drive (43) for driving the weighing pan (41) to tilt. The control unit (5) is electrically connected to the front blocking cylinder (31), the rear blocking cylinder (32), the weighing sensor (42), and the tilting drive (43). It is used to control the rear blocking cylinder (32) and the front blocking cylinder (31) to extend and retract alternately so that a single roller (1) to be tested falls into the weighing pan (41). The control unit (5) determines the mass of the roller (1) to be tested based on the weighing signal collected by the weighing sensor (42), and drives the tilting drive (43) to tilt the weighing pan (41) to unload the material based on the determination result.

2. The automated roller weighing device with dual-cylinder staggered sorting according to claim 1, characterized in that: The weighing and sorting mechanism (4) further includes a sorting channel (44) located below the weighing pan (41). The sorting channel (44) includes a qualified side slide groove (441) located on the right side of the weighing pan (41) and an unqualified side slide groove (442) located on the left side of the weighing pan (41). The flipping drive (43) is a flipping cylinder located at the bottom of the weighing pan (41) for controlled driving of the weighing pan (41) to tilt to the left or right.

3. The automated roller weighing device with dual-cylinder staggered sorting according to claim 1, characterized in that: It also includes an automatic feeding system (6), which includes a disc-type vibratory feeder (61) connected to the conveying track (2) and a vibration controller (62) connected to the control unit (5); the side of the conveying track (2) is provided with a photoelectric sensor (21) for detecting the material level at the end of the conveying track (2), and the vibration controller (62) adjusts the vibration frequency according to the material level.

4. The automated roller weighing device with dual-cylinder staggered sorting according to claim 1, characterized in that: It also includes a slide rail (22) installed on the side of the conveying track (2), the front blocking cylinder (31) and the rear blocking cylinder (32) are slidably installed on the slide rail (22), and the slide rail (22) is provided with a locking mechanism for locking the relative position of the front blocking cylinder (31) and the rear blocking cylinder (32) to adjust the effective distance L.

5. The automated roller weighing device with dual-cylinder staggered sorting according to claim 1, characterized in that: Both the front blocking cylinder (31) and the rear blocking cylinder (32) are equipped with pneumatic speed control valves at their air passage interfaces to adjust the impact speed when the blocking end extends.

6. The automated roller weighing device with dual-cylinder staggered sorting according to claim 1, characterized in that: An inclined guide swashplate (411) is provided between the end of the conveying track (2) and the weighing pan (41) to guide the roller (1) to be tested to smoothly transition into the weighing pan (41).

7. The automated roller weighing device with dual-cylinder staggered sorting according to claim 1, characterized in that: The outer cover of the weighing and sorting mechanism (4) is provided with a transparent windproof cover, which covers the weighing pan (41) and the weighing sensor (42) inside to isolate the interference of external airflow on the weighing process.

8. A method for automated weighing control of rollers using a dual-cylinder staggered sorting system, applied to the automated weighing device for rollers using a dual-cylinder staggered sorting system as described in any one of claims 1 to 7, characterized in that... Includes the following steps: Step S1: Control the rear blocking cylinder (32) to remain extended to intercept the rear roller, and then control the front blocking cylinder (31) to retract, so that the only roller (1) to be tested located between the front blocking cylinder (31) and the rear blocking cylinder (32) slides down to the weighing pan (41). Step S2: Collect the weighing signal output by the weighing sensor (42) during the process of the roller (1) falling into the weighing pan (41), and calculate the mass of the roller (1). Step S3: Compare the calculated mass with the preset tolerance zone to obtain the comparison result; Step S4: Drive the flipping drive (43) to tilt the weighing pan (41) according to the comparison result to complete the unloading, and then control the weighing pan (41) to return to the horizontal state; Step S5: Control the front blocking cylinder (31) to extend to block the outlet of the conveying track (2), then control the rear blocking cylinder (32) to briefly retract to allow the next test roller (1) to enter between the front blocking cylinder (31) and the rear blocking cylinder (32), then control the rear blocking cylinder (32) to extend again and return to step S1.

9. The automated weighing control method for rollers in dual-cylinder staggered sorting according to claim 8, characterized in that, In step S2, the calculation of the mass of the roller (1) to be tested specifically includes: The impact waveform of the falling plate collected by the weighing sensor (42) is captured, and the intermediate trend line of the impact waveform is fitted by an algorithm. The steady-state mass value after the waveform oscillation disappears is calculated based on the intermediate trend line.

10. The automated weighing control method for rollers in dual-cylinder staggered sorting according to claim 8, characterized in that, The recipe initialization step is included before step S1: Select the target parameter formula corresponding to the specifications of the roller (1) to be tested. The control unit (5) automatically loads the target weight reference value and the upper and lower limits of the tolerance zone in the parameter formula, and adjusts the effective distance L between the front blocking cylinder (31) and the rear blocking cylinder (32) according to the outer diameter D of the roller (1) to be tested.

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