LED automatic sorting system and implementation method

Abstract

The present application relates to the field of workshop equipment, in particular to a kind of LED automation sorting system and implementation method, wherein a kind of LED automation sorting system includes reel, conveying belt, empty carrier shelf, backup shelf, backup robot, order system, visual identification system, laser sensor and central control system.The beneficial effects of the present application are embodied in that, in order to improve the efficiency of sorting, high-speed automated sorting equipment is used, combined with advanced visual identification system and sensor technology, different specifications, models of LED can be quickly identified and classified, visual identification system can continue to run, greatly improve the sorting speed of production line, avoid the efficiency bottleneck of manual sorting;Through the automatic control of central control system, according to the order demand, the sorting speed and batch processing capacity are flexibly adjusted, especially suitable for responding to the demand of large-scale production of LED industry.

Description

Technical Field

[0001] This invention relates to the field of workshop equipment technology, and in particular to an LED automated sorting system and its implementation method. Background Technology

[0002] During the production process, enterprises need to spend a lot of manpower on sorting, checking, and packaging. In this process, mis-packaging and missing packages often occur, which not only consumes a lot of manpower, but also makes it difficult to guarantee accuracy. In order to improve accuracy, the entire process from sorting to packaging has been automated and managed, and personnel only handle abnormal scenarios that trigger system alarms.

[0003] Existing technologies mostly rely on manual sorting, which has the following drawbacks: First, LED products are complex and difficult to sort. Some LEDs may look similar but have different technical parameters, requiring constant reference to order or label information during manual sorting, increasing sorting time and difficulty. Second, sorting speed is slow and production efficiency is low. LED production lines typically need to operate at high speeds to meet the demands of large orders, and manual sorting cannot keep up with the efficient pace of the production line, especially when LED products are diverse and batches are large. Summary of the Invention

[0004] To address the above problems, the present invention provides the following technical solution: This invention discloses an automated LED sorting system, including reels, conveyor belts, empty racks, backup racks, a backup robot, an order system, a vision recognition system, laser sensors, and a central control system. The reels are used to load LEDs and are labeled with barcodes. The conveyor belt transports the reels to a sorting area at its end and includes a drive motor. The empty racks store reels without LEDs and are marked with a first storage location. The backup racks store reels loaded with LEDs and already sorted, and are marked with a second storage location. The backup robot automatically picks up the reels and places them in the empty racks. The system consists of a carrier rack or a backup rack; an order system for receiving, processing, and tracking order information; a vision recognition system for quickly identifying and classifying LEDs of different specifications and models, including an RGB camera for capturing images of the reels; a laser sensor for detecting the position of the reels; and a central control system for controlling the entire sorting system. The central control system is electrically connected to the drive motor, backup robot, vision recognition system, and laser sensor. The central control system and the order system exchange data via an API interface, with the order system transmitting order information and production plans to the central control system through the API interface.

[0005] Preferably, the backup robot is located at one end of the conveyor belt, the empty vehicle rack and the backup rack are located on the same side of the backup robot, the backup robot is a robotic arm, both the robotic arm and the conveyor belt are equipped with laser sensors, and an RGB camera is located on the robotic arm.

[0006] Preferably, the LED automated sorting system also includes a buffer rack, which is a semi-circular structure located on the other side of the backup robot, for temporary storage of reels. The buffer rack is marked with a third storage location.

[0007] Preferably, the central control system includes a database for recording the status of the first, second, and third storage locations.

[0008] A method for implementing an automated LED sorting system, the automated LED sorting system employing the aforementioned automated LED sorting system, includes the following steps: S1. The conveyor belt transports the reels to the sorting area; S2. The laser sensor on the conveyor belt detects the position of the reel and sends the position information to the central control system. The central control system drives the RGB camera to capture an image of the reel containing the barcode and LEDs. The image is transmitted to the vision recognition system via the network. The vision recognition system uses a barcode recognition algorithm to recognize the barcode and sends the recognized barcode information to the central control system. The vision recognition system uses an image processing algorithm to accurately identify the packaging form, specifications and model of the LEDs and sends the identified LED information to the central control system. S3. The central control system receives barcode information sent by the visual recognition system. The central control system calls the order system through the API interface to query the order corresponding to the barcode information. The order system finds the corresponding order and feeds it back to the central control system. S4. The central control system calls the database based on the returned order information, performs data queries, and determines whether there is a second storage location on the backup shelf. The second storage location is required to have the same specifications and model as the LEDs in the order.

[0009] Preferably, step S4 further includes the following steps: S41: If a second storage location exists, determine whether the number of reels in the second storage location meets the packaging requirements after adding the reels; S411: If the packaging requirements are met, determine the status of the second storage location; S4111: If other backup robots are using the second storage location and the second storage location is locked, the backup robot will wait until the second storage location is unlocked, then proceed to step S4112. S4112: If other backup robots are not using the second storage location, the laser sensor on the conveyor line detects the position of the reel and sends the position information to the central control system. The central control system then arranges for a robotic arm to pick up the reel, collect it in the second storage location, and push the reel in the second storage location to the packaging area. S412: If the packaging requirements are not met, the laser sensor on the conveyor line detects the position of the reel and sends the position information to the central control system. The central control system then arranges for a robotic arm to pick up the reel and collect it in the second storage location. S42: If no second storage location exists, check if there is an empty second storage location on the spare parts shelf; S421: If an empty second storage location exists, determine the status of the empty second storage location; S4211: If other backup robots are using an empty second storage location, and the empty second storage location is locked, the backup robot will wait until the empty second storage location is unlocked, and then proceed to step S4212. S4212: If other backup robots are not using the empty second storage location, the laser sensor on the conveyor line detects the position of the reel and sends the position information to the central control system. The central control system then arranges for a robotic arm to pick up the reel and place it in the empty second storage location. S422: If there is no empty second storage location, the central control system will issue an alert to remind manual handling of the reel.

[0010] Preferably, when the central control system arranges the robotic arm to pick up the reel, it uses inverse kinematics and path optimization algorithms to plan the optimal motion path and action execution of the robotic arm.

[0011] Preferably, during the waiting process, the robot first places the reel in the first storage location B on the buffer rack, and continues to process the next reel until the second storage location or an empty second storage location is unlocked.

[0012] The beneficial effects of this invention are reflected in the fact that, in order to improve sorting efficiency, high-speed automated sorting equipment is adopted, combined with advanced visual recognition system and sensor technology, which can quickly identify and classify LEDs of different specifications and models. The visual recognition system can operate continuously, greatly improving the sorting speed of the production line and avoiding the efficiency bottleneck of manual sorting. Through the automated control of the central control system, the sorting speed and batch processing capacity can be flexibly adjusted according to order requirements, which is particularly suitable for meeting the needs of large-scale production in the LED industry. Attached Figure Description

[0013] Figure 1 This is a perspective view of an automated LED sorting system provided by the present invention.

[0014] Figure 2The flowchart illustrates a method for implementing an automated LED sorting system provided by this invention.

[0015] In the diagram: 1-Reel; 2-Conveyor belt; 3-Empty rack; 4-Filing rack; 5-Filing robot; 6-Buffer rack. Detailed Implementation

[0016] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0017] Reference Figures 1-2 An automated LED sorting system includes a reel 1, a conveyor belt 2, an empty rack 3, a backup rack 4, a backup robot 5, an order system, a vision recognition system, a laser sensor, and a central control system. The reel 1 is used to load LEDs and is equipped with a barcode. The conveyor belt 2 transports the reel 1 to a sorting area at its end, and includes a drive motor. The empty rack 3 stores reels 1 without LEDs and is marked with a first storage location. The backup rack 4 stores reels 1 loaded with LEDs and already sorted, and is marked with a second storage location. The backup robot 5 automatically picks up the reel 1 and sorts it. 1. Place the reel 1 on the empty rack 3 or store it on the backup rack 4; The order system is used to receive, process, and track order information; The visual recognition system is used to quickly identify and classify LEDs of different specifications and models. The visual recognition system includes an RGB camera for capturing images of the reel 1; The laser sensor is used to detect the position of the reel 1; The central control system is used to control the operation of the entire sorting system. The central control system is electrically connected to the drive motor, the backup robot 5, the visual recognition system, and the laser sensor. The central control system and the order system exchange data through an API interface. The order system transmits order information and production plans to the central control system through the API interface.

[0018] Conveyor belt 2 transports reel 1 from upstream equipment into the sorting area. Upon arrival, a laser sensor detects the reel 1's position and feeds this information back to the central control system. The central control system then issues a gripping command to the robot 5, enabling automatic gripping and sorting. The backup robot 5 automatically grips reel 1 and places it on the empty rack 3 or stores it in the backup rack 4. Conveyor belt 2 continues to transport the next reel 1.

[0019] To improve sorting efficiency, high-speed automated sorting equipment is adopted, combined with advanced vision recognition systems and sensor technology, which can quickly identify and classify LEDs of different specifications and models. The vision recognition system can operate continuously, greatly improving the sorting speed of the production line and avoiding the efficiency bottleneck of manual sorting. Through the automated control of the central control system, the sorting speed and batch processing capacity can be flexibly adjusted according to order requirements, which is particularly suitable for meeting the needs of large-scale production in the LED industry.

[0020] In some implementations, refer to Figure 1 The backup robot 5 is located at one end of the conveyor belt 2. The empty vehicle rack 3 and the backup rack 4 are located on the same side of the backup robot 5. The backup robot 5 is a robotic arm. Both the robotic arm and the conveyor belt 2 are equipped with laser sensors, and an RGB camera is located on the robotic arm.

[0021] This invention replaces manual operation with an automated robotic arm, reducing worker fatigue and the associated labor intensity. Simultaneously, the system can handle delicate LED components, reducing LED product damage and improving overall sorting safety. The automation system effectively reduces worker contact with products, lowering the risk of damage to LED products caused by improper operation or environmental factors such as static electricity and dust. The robotic arm can be replaced by other gripping devices. Laser sensors mounted on the robotic arm monitor the surrounding environment in real time, preventing collisions and protecting the equipment. As the reel 1 moves along the conveyor line, its position is monitored in real time by laser sensors installed in the sorting area, providing feedback to the central control system. This allows the central control system to dynamically adjust task allocation based on the shelf load, the material feed rate of the reel 1 on the conveyor line, and the robotic arm's operating rhythm, ensuring a smooth and efficient process. The central control system adjusts the material feed rate of the conveyor line by changing the speed of the drive motor. The RGB camera is located on the robotic arm. When the robotic arm approaches the reel 1, it takes a close-up picture of the reel 1. Combined with the algorithm of the visual recognition system, it quickly and accurately identifies the specifications and models of the LEDs on the reel 1, as well as the barcode on the reel 1, thereby speeding up the sorting process.

[0022] Furthermore, refer to Figure 1 The LED automated sorting system also includes a buffer rack 6, which is a semi-circular structure located on the other side of the backup robot 5 and is used for temporary storage of reels 1. The buffer rack 6 is marked with a third storage location.

[0023] The inventors discovered that when the backup rack 4 or the empty rack 3 is full and needs to be replaced, or when the second storage location on the backup rack 4 is locked, or when the first storage location on the empty rack 3 is locked, production may be interrupted because there is no second storage location or the first storage location can hold the reel 1. The buffer rack 6 is used to temporarily store the reels 1 that have been sorted but have not yet been finally returned to their original positions. This provides more buffer space for the sorting system and avoids production interruptions caused by the lack of a second or first storage location. The semi-circular structure design allows the robotic arm to access the third storage location in different positions more quickly, reducing the travel distance and time of the robotic arm and improving operational efficiency.

[0024] Furthermore, the central control system includes a database for recording the status of the first, second, and third storage locations.

[0025] The database contains three tables, each recording the status of a storage location (first, second, and third), and the quantity and model of the reels 1 placed in each location. The status includes two categories: idle and locked. Whenever the backup robot 5 places a reel 1 into a storage location, the central control system updates the database. By querying the database, the central control system knows which items are idle and which are locked. When an empty rack 3, backup rack 4, or buffer rack 6 reaches its designated capacity, the central control system issues a notification, reminding staff to move the fully loaded rack to the downstream operating area.

[0026] Reference Figure 2 An implementation method for an automated LED sorting system, the automated LED sorting system adopting the above-mentioned automated LED sorting system, includes the following steps: S1, Conveyor belt 2 conveys reel 1 to the sorting area; S2. The laser sensor on the conveyor belt 2 detects the position of the reel 1 and sends the position information to the central control system. The central control system drives the RGB camera to capture an image of the reel 1 containing barcodes and LEDs. The image is transmitted to the vision recognition system via the network. The vision recognition system uses a barcode recognition algorithm to recognize the barcode and sends the recognized barcode information to the central control system. The vision recognition system uses an image processing algorithm to accurately identify the packaging form, specifications and model of the LEDs and sends the identified LED information to the central control system. S3. The central control system receives barcode information sent by the visual recognition system. The central control system calls the order system through the API interface to query the order corresponding to the barcode information. The order system finds the corresponding order and feeds it back to the central control system. S4. The central control system calls the database based on the returned order information, performs data query, and determines whether there is a second storage location on the backup shelf 4. The second storage location is required to have the same specifications and model as the LEDs in the order.

[0027] In some implementations, step S4 further includes the following steps: S41: If a second storage location exists, determine whether the quantity of reel 1 in the second storage location meets the packaging requirements after adding reel 1. S411: If the packaging requirements are met, determine the status of the second storage location; S4111: If other backup robot 5 is using the second storage location and the second storage location is locked, backup robot 5 will wait until the second storage location is unlocked, then proceed to step S4112. S4112: If other backup robots 5 are not using the second storage location, the laser sensor on the conveyor line detects the position of the reel 1 and sends the position information to the central control system. The central control system arranges the robotic arm to pick up the reel 1, collect it in the second storage location, and push the reel 1 in the second storage location to the packaging area. The visual recognition system can automatically identify the barcodes of LED products and synchronize them to the central control system. The central control system then calls the order system to match the barcode information with the order information in real time, ensuring that each product is sorted into the correct packaging area and avoiding human error.

[0028] S412: If the packaging requirements are not met, the laser sensor on the conveyor line detects the position of reel 1 and sends the position information to the central control system. The central control system then arranges for a robotic arm to pick up reel 1 and collect it in the second storage location. S42: If there is no second storage location, check if there is an empty second storage location on the backup rack 4; S421: If an empty second storage location exists, determine the status of the empty second storage location; S4211: If other backup robots 5 are using an empty second storage location, and the empty second storage location is locked, backup robot 5 will wait until the empty second storage location is unlocked, and then proceed to step S4212. S4212: If other backup robots 5 are not using the empty second storage location, the laser sensor on the conveyor line detects the position of reel 1 and sends the position information to the central control system. The central control system then arranges for a robotic arm to pick up reel 1 and place it in the empty second storage location. S422: If there is no empty second storage location, the central control system issues a reminder to manually handle reel 1.

[0029] Furthermore, when the central control system arranges for the robotic arm to pick up reel 1, it uses inverse kinematics and path optimization algorithms to plan the optimal motion path and action execution for the robotic arm.

[0030] The central control system first precisely positions the reel 1 on the conveyor line based on position data fed back by the laser sensors. Then, using inverse kinematics and path optimization algorithms, the central control system calculates the optimal motion path and action execution for the robotic arm, controlling it to grasp the reel 1, thus ensuring operational stability and efficiency.

[0031] Furthermore, while the robot is waiting, it first places reel 1 in the first storage location B on the buffer rack 6, and continues to process the next reel 1 until the second storage location or an empty second storage location is unlocked.

[0032] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An automated LED sorting system, characterized in that: include: Reel, used to load LEDs, the reel is equipped with a barcode; A conveyor belt is used to transport reels to a sorting area at the end of the conveyor belt, and the conveyor belt includes a drive motor; Empty racks are used to store reels without LEDs; the first storage location is marked on the empty racks. The backup rack is used to store reels loaded with LEDs that have been sorted. The backup rack is marked with a second storage location. The filing robot is used to automatically grab reels and place them on empty carrier shelves or store them in filing shelves; An order system is used to receive, process, and track order information; A visual recognition system for quickly identifying and classifying LEDs of different specifications and models, including an RGB camera for capturing images from a reel; Laser sensors are used to detect the position of the reel; The central control system is used to control the operation of the entire sorting system. The central control system is electrically connected to the drive motor, backup robot, vision recognition system and laser sensor. The central control system and the order system exchange data through API interface. The order system transmits order information and production plan to the central control system through API interface.

2. The LED automated sorting system according to claim 1, characterized in that: The backup robot is located at one end of the conveyor belt, and the empty vehicle rack and the backup rack are located on the same side of the backup robot. The backup robot is a robotic arm, and both the robotic arm and the conveyor belt are equipped with laser sensors. An RGB camera is located on the robotic arm.

3. The LED automated sorting system according to claim 2, characterized in that: It also includes a cache rack, which is a semi-circular structure located on the other side of the backup robot, for temporary storage of reels. The cache rack is marked with a third storage location.

4. The LED automated sorting system according to claim 3, characterized in that: The central control system includes a database for recording the status of the first, second, and third storage locations.

5. A method for implementing an automated LED sorting system, characterized in that: The LED automated sorting system adopts the LED automated sorting system as described in claim 4, and includes the following steps: S1. The conveyor belt transports the reels to the sorting area; S2. The laser sensor on the conveyor belt detects the position of the reel and sends the position information to the central control system. The central control system drives the RGB camera to capture an image of the reel containing the barcode and LEDs. The image is transmitted to the vision recognition system via the network. The vision recognition system uses a barcode recognition algorithm to recognize the barcode and sends the recognized barcode information to the central control system. The vision recognition system uses an image processing algorithm to accurately identify the packaging form, specifications and model of the LEDs and sends the identified LED information to the central control system. S3. The central control system receives barcode information sent by the visual recognition system. The central control system calls the order system through the API interface to query the order corresponding to the barcode information. The order system finds the corresponding order and feeds it back to the central control system. S4. The central control system calls the database based on the returned order information, performs data queries, and determines whether there is a second storage location on the backup shelf. The second storage location is required to have the same specifications and model as the LEDs in the order.

6. The method for implementing an automated LED sorting system according to claim 5, characterized in that: Step S4 also includes the following steps: S41: If a second storage location exists, determine whether the number of reels in the second storage location meets the packaging requirements after adding the reels; S411: If the packaging requirements are met, determine the status of the second storage location; S4111: If other backup robots are using the second storage location and the second storage location is locked, the backup robot will wait until the second storage location is unlocked, then proceed to step S4112. S4112: If other backup robots are not using the second storage location, the laser sensor on the conveyor line detects the position of the reel and sends the position information to the central control system. The central control system then arranges for a robotic arm to pick up the reel, collect it in the second storage location, and push the reel in the second storage location to the packaging area. S412: If the packaging requirements are not met, the laser sensor on the conveyor line detects the position of the reel and sends the position information to the central control system. The central control system then arranges for a robotic arm to pick up the reel and collect it in the second storage location. S42: If no second storage location exists, check if there is an empty second storage location on the spare parts shelf; S421: If an empty second storage location exists, determine the status of the empty second storage location; S4211: If other backup robots are using an empty second storage location, and the empty second storage location is locked, the backup robot will wait until the empty second storage location is unlocked, and then proceed to step S4212. S4212: If other backup robots are not using the empty second storage location, the laser sensor on the conveyor line detects the position of the reel and sends the position information to the central control system. The central control system then arranges for a robotic arm to pick up the reel and place it in the empty second storage location. S422: If there is no empty second storage location, the central control system will issue an alert to remind manual handling of the reel.

7. The method for implementing an automated LED sorting system according to claim 6, characterized in that: When the central control system arranges for the robotic arm to pick up the reel, it uses inverse kinematics and path optimization algorithms to plan the optimal motion path and action execution for the robotic arm.

8. The method for implementing an automated LED sorting system according to claim 6, characterized in that: While the robot is waiting, it first places the reel in the first storage location B on the buffer rack and continues to process the next reel until the second storage location or an empty second storage location is unlocked.

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