A cutting control system and method for a cold shearing machine based on vision and multi-sensor fusion

Abstract

The application relates to a cutting control system and method for a cold shearing machine based on vision and multi-sensor fusion, and relates to the technical field of high-speed bar production. The system comprises a cooling bed output roller way, a cold shearing machine front roller way, a cold shearing machine, a cold shearing machine rear roller way, a fixed-length baffle, an operation table and a detection device group. The operation table comprises a manual / automatic switching switch and a man-machine interface. Material detection sensors B, C and D are arranged on the cooling bed output roller way. A material detection sensor A is arranged on the cold shearing machine front roller way. A material detection sensor A1 is arranged on the cold shearing machine rear roller way. A camera S is arranged at the cutting edge of the cold shearing machine. A camera S1 is arranged at the fixed-length baffle. The control module of the system adopts a PLC and an image processing industrial computer. The application has the effect of improving the control precision of the cold shearing machine.

Description

Technical Field

[0001] This application relates to the field of high-speed bar production technology, and in particular to a shearing control system and method for a cold shearing machine based on vision and multi-sensor fusion. Background Technology

[0002] High-speed bar production lines are industrial production lines that use high-speed steel rolling systems to achieve efficient bar rolling. Compared with traditional ordinary bar production lines, they have core advantages such as fast rolling speed, high product precision, high yield, and large capacity. They have now become the mainstream production process for bar products such as rebar.

[0003] In high-speed bar production lines, the cold shear is the final step in cutting finished products to length. Its control accuracy directly affects the yield and production efficiency. Currently, existing production lines mainly have the following defects and shortcomings: (1) Manual operation mode relies on manual labor, which has significant drawbacks: In manual mode, each piece of equipment (roller conveyor, cold shear, baffle) is operated by the operator. The operator needs to observe the position of the rebar with the naked eye and control the start and stop of the roller conveyor and the timing of shearing based on experience. This method has problems such as large deviation in shearing length, frequent equipment impact, multiple operators required per shift, and extremely high labor intensity. Moreover, the high temperature and dust environment poses a serious health hazard to workers; (2) Existing automatic solutions lack precise visual closed loop and have poor adaptability: Although some production lines are equipped with basic photoelectric sensors and length baffles, they rely solely on switch signals. The system cannot determine whether there is steel or not. It cannot obtain the precise position and shape of the end of the rebar. Especially in the fixed length stage, when the end is bent or tilted, even if it hits the baffle, the end face cannot be completely fitted, resulting in a poor actual fixed length, which requires manual intervention to correct; (3) Lack of dynamic calculation of the cutting head accumulation, resulting in material waste: the existing automatic cutting head is mostly fixed number of times or fixed total length, and does not make "adaptive adjustment of the last cut allowance" according to the actual extension length, which often results in overcutting or undercutting, reducing the yield; (4) Short tails cannot be automatically handled and rely on manual cleaning: when the remaining length of the multiple length is less than one fixed length, the existing system cannot automatically identify and handle it, which often results in the tail material accumulating at the fixed length baffle or on the shearing roller, which requires manual intervention to clean, increasing labor intensity and downtime.

[0004] Based on the above, there is an urgent need for a vision and multi-sensor fusion-based cold shear machine cutting control system and method to improve the defects and shortcomings of the existing technology. Summary of the Invention

[0005] To address the aforementioned issues, this application provides a vision and multi-sensor fusion-based cold shear machine cutting control system and method.

[0006] Firstly, the technical solution provided in this application for a cold shear machine shearing control system based on vision and multi-sensor fusion is as follows: A vision-based and multi-sensor fusion-based cold shearing machine control system includes a cooling bed output roller conveyor, a cold shearing front roller conveyor, a cold shearing machine, a cold shearing rear roller conveyor, a length-fixing baffle, an operating table, and a detection device group. The operating table includes a manual / automatic switch and a human-machine interface. Material detection sensors B, C, and D are installed on the cooling bed output roller conveyor, material detection sensor A is installed on the cold shearing front roller conveyor, and material detection sensor A1 is installed on the cold shearing rear roller conveyor. A camera S is installed at the blade of the cold shearing machine, and a camera S1 is installed at the length-fixing baffle. The control module of the system adopts a PLC and an image processing industrial control computer.

[0007] Preferably, the system includes a manual mode and an automatic mode. In the manual mode, the selection is made via a switch on the control panel, and each device is controlled one by one by the control panel buttons or joysticks. The visual signals are only used for monitoring and display and do not participate in closed-loop control. In the automatic mode, the operator needs to input the core process parameters through the human-machine interface before starting the machine: total length of the multiple-length cut L0, total length of the cold shear head cut Q1, single cut length of the head cut Q2, finished product length D, and minimum tail length discard threshold Tmin. After the parameters are entered, the system enters an automatic standby state, and all subsequent actions are automatically triggered and executed cyclically by the sensor signals of the vision inspection machine.

[0008] Preferably, after the system starts running automatically, it will cycle through the following states until a stop command is received: standby, head cutting cycle, post-cutting conveying connection, fixed length bonding cycle, fixed length cutting and short tail judgment, finished product output / short tail removal and baffle reset, and return to standby.

[0009] The second invention, a shearing control method for a cold shear machine based on vision and multi-sensor fusion, provides the following technical solution: A shearing control method for a cold shear machine based on vision and multi-sensor fusion includes the following steps: S1: Automatic head-cutting cycle; S2: Post-cutting conveyor connection; S3: Automatic length-fitting cycle; S4: Fixed-length cutting and short tail judgment; S5: Automatic processing flow for short tail rulers; S6: Finished product output and baffle reset.

[0010] Preferably, in step S1: The system scans the sensor combination signals in real time. When the following three conditions are met simultaneously, the cutting flag Q is automatically triggered, i.e., Q=1. Condition a: Material detection B, C, and D on the output roller conveyor of the cooling bed all detect rebar, ensuring that the entire steel bar has completely left the cooling bed; Condition b: Material detection A on the roller conveyor before cold shearing has no signal; Condition c: After cold shearing, the roller conveyor has no signal from the material detection A1. When Q=1, the system automatically starts the output roller conveyor of the cooling bed and the roller conveyor before the cold shear, conveying the rebar forward to the blade of the cold shear machine; step S1 also includes slow positioning and visual ranging: when the material detection A of the roller conveyor before the cold shear detects a signal of steel, the system automatically switches the speed of all currently running rollers from "high-speed feeding" to "slow feeding speed" to ensure subsequent positioning accuracy; at this time, the camera S at the blade of the cold shear machine begins to collect images in real time, and identifies the end position of the rebar through the edge detection algorithm, and calculates the actual extension length L from the end to the shear blade; Step S1 also includes single-blade shearing and cumulative allowance adaptive: the system has a built-in accumulator Sum_H with an initial value of 0: when the camera S detects that the extension length L is equal to Q2, the system immediately triggers the roller conveyor stop command and simultaneously sends a single shearing action command to the cold shear machine to complete the current blade shearing; After the cutting is completed, the accumulator is updated: Sum_H = Sum_H + Q2; the system performs a margin judgment: calculates the remaining cutting length Rem_H = Q1 – Sum_H; if Rem_H ≥ Q2, the above steps continue to be repeated; if Rem_H < Q2 and Rem_H > 0, the system automatically sets the target cutting length of the last cut to Rem_H, and triggers the last cutting when the camera S detects L = Rem_H to avoid overcutting; when the accumulated cutting length Sum_H = Q1, it indicates that all irregular segments of the head have been removed, the system automatically resets the cutting head flag Q, and the cutting head cycle ends.

[0011] Preferably, in step S2: After the head-cutting mark Q is reset, the system detects the signals from the material detection A1 on the cold shearing roller conveyor and the camera S1 at the fixed-length baffle: when A1 detects no material and S1 detects no rebar in the area below the baffle, the system automatically triggers the roller conveyor steel feeding command, starts the pre-shearing and post-shearing roller conveyors, and continues to convey the head-cut rebar backward into the fixed-length shearing area.

[0012] Preferably, in step S3: S31: End face fit status monitoring. When the rebar is conveyed to the fixed length baffle, the camera S1 continuously collects images of the baffle area and intelligently identifies the fit status between the end of the rebar and the vertical end face of the fixed length baffle. S32: Fitting determination based on adaptive collision alignment action The system has a built-in bonding retry counter, Retry, with an initial value of 0 and a maximum allowed number of retries of 2. Case A: If S1 detects that the end face is completely in contact with the baffle, the system directly issues a "cutting allowed" signal, proceeds to step S4, and clears Retry to zero. Case B: If S1 detects the presence of a gap or end face inclination, the system executes the following logic: a. Retry=Retry+1; determine the value of Retry; If Retry≤2: The system automatically performs the fine adjustment alignment action: trigger the roller table to retreat slowly until the end retreats to a position 50mm away from the baffle end face and stops; after a pause, trigger the roller table to advance slowly, so that the end hits the baffle at a low speed; after the impact, S1 detects the fitting state again; if normal, proceed to Case A, if still abnormal, return to the start of Case B to continue the next round of retry; If Retry≥3: The system determines that the end of this section of rebar has severe deformation or foreign matter, will no longer continue to perform the alignment action, but directly issue a "shear allow" command to allow the cold shear to perform shearing, and simultaneously trigger a "fitting abnormality alarm" signal to inform the operator that this section of fixed length may have a length deviation or end defect, so as to facilitate subsequent sorting processing. After the shearing is completed, the system automatically resets Retry to zero and restores the normal process.

[0013] Preferably, in step S4: After S1 confirms that the fitting is normal, the system immediately triggers the cold shear to execute the fixed-length shearing command. After the shearing is completed, the system collects the post-shearing state in real time and performs a short tail length judgment: The system calculates the remaining multiple length: Rem_L=L0-Q1-n×D; if Rem_L≥D, the normal process continues; if Rem_L<D and Rem_L>0, proceed to step S5.

[0014] Preferably, in step S5: When the system determines that the remaining length Rem_L<D and Rem_L>0, the short tail length processing mode is triggered: S51: Short tail length alarm and identification, the system triggers a "short tail length alarm" signal to remind the monitoring personnel that the current tail material processing stage has been entered; S52: The baffle is automatically opened, the system automatically triggers the fixed-length baffle lifting command, and no longer performs the end face fitting action to avoid invalid impact between the short tail length and the baffle; S53: Short tail length conveying, the system keeps the pre-shearing roller table and the post-shearing roller table running continuously, and conveys the short tail length directly to the downstream special short length collection area via the post-shearing roller table; S54: Short tail length shearing, if the length of the short tail length exceeds the upper limit of roller table conveying allowed by the equipment, the system can automatically trigger the cold shear to cut it into 2-3 sections for easy collection; if the short tail length is relatively short, it can be directly conveyed to the short length collection tank without shearing; S55: Zone reset and cycle restart. When the camera S1 detects that there is no threaded steel under the baffle and A1 detects no material, the system determines that all short tail lengths have been completely removed, automatically resets the fixed-length counter n, turns off the short tail length alarm, and sends the signal "All single multiple lengths have been processed" to the central control. The system returns to the standby state of step S1 and waits for the arrival of the next multiple length.

[0015] Preferably, in step S6: After the shearing is completed, the system simultaneously detects that the fixed-length baffle is automatically lifted; The system waits for the steel demand signal from the downstream process. When receiving the steel demand signal, the system starts the post-shear roller table to fully convey the finished threaded steel to the downstream finished product collection area; When the camera S1 detects that there is no threaded steel in the area under the baffle, the system automatically issues a command to lower the fixed-length baffle, so that the baffle is reset to the working position; After the baffle is reset, the system automatically returns to step S3 to start the next fixed-length shearing cycle, until step S4 triggers the short tail judgment and proceeds to step S5.

[0016] In summary, the present application includes at least the following beneficial technical effects: 1. The present application supports free switching between dual modes to adapt to different working conditions. The present application has both manual and automatic modes: the manual mode can be used for commissioning, maintenance or abnormal conditions; one-key switching to automatic mode during normal production, with high flexibility; 2. The present application can adaptively cut the remaining head material, significantly improving the finished product rate. Through the dynamic comparison between the accumulator and the remaining amount (when Rem_H<Q2, cut according to the actual length), the over-cutting waste caused by the fixed step size is completely eliminated, and the reduction of head waste directly improves economic benefits; 3. The present application can achieve closed-loop fine adjustment by alignment collision, and the fixed-length accuracy reaches the millimeter level. The camera S1 feeds back the fitting state in real time and executes the "slow retract - slow advance" alignment collision cycle, ensuring that the end face fits consistently each time, and the fixed-length length deviation can be controlled within ±1.5mm, far exceeding the industry standard; 4. The present application can realize fully automatic removal of short tail lengths and eliminate manual cleaning. When the remaining length is less than the fixed length, the system automatically opens the baffle to convey the short tail length to the special short length collection area, completely solving the pain points of tail material accumulation and reliance on manual cleaning in traditional solutions, greatly reducing labor intensity and eliminating safety risks; 5. The present application adopts multi-sensor and vision fusion, with logic interlock for foolproofing: the 1-out-of-3 signal of B / C / D avoids false triggering; the cross interlock of A, A1 and the visual signals S / S1 ensures that no false shearing or steel piling accidents occur under any abnormal material flow; 6. This application features a fully automated cycle without manual intervention. From triggering the head cutting, cumulative shearing, conveying and connecting, fitting and fine-tuning (including fault tolerance), baffle linkage, short tail removal to finished product output, the entire process is automatically connected. It can reduce the number of staff by 2 to 3 people per shift and completely eliminate the safety risks of high-temperature operations. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of a cold shear machine shearing control system based on vision and multi-sensor fusion according to an embodiment of this application. Detailed Implementation

[0018] The following is in conjunction with the appendix Figure 1 This application will be described in further detail.

[0019] This application discloses a shearing control system for a cold shear machine based on vision and multi-sensor fusion. (Refer to...) Figure 1 , A vision-based and multi-sensor fusion-based cold shearing machine control system includes a cooling bed output roller conveyor, a cold shearing front roller conveyor, a cold shearing machine, a cold shearing rear roller conveyor, a length-fixing baffle, an operating table, and a detection device group. The operating table includes a manual / automatic switch and a human-machine interface. Material detection sensors B, C, and D are installed on the cooling bed output roller conveyor, material detection sensor A is installed on the cold shearing front roller conveyor, and material detection sensor A1 is installed on the cold shearing rear roller conveyor. A camera S is installed at the blade of the cold shearing machine, and a camera S1 is installed at the length-fixing baffle. The system's control module uses a PLC and an image processing industrial control computer.

[0020] Reference Figure 1 The system includes manual and automatic modes. In manual mode, the selection is made via a switch on the control panel. Each piece of equipment (roller conveyor, cold shear machine, baffle) is controlled one by one by the control panel buttons or joysticks. The visual signals are only used for monitoring and display and do not participate in closed-loop control. In automatic mode, the operator needs to enter the core process parameters through the human-machine interface (HMI) before starting the machine: total length of multiple length L0, total shearing length of the cold shear head Q1, single shearing length of the head Q2, finished product length D, and minimum tail length discard threshold Tmin. After the parameters are entered, the system enters an automatic standby state, and all subsequent actions are automatically triggered and executed cyclically by the sensor signals of the vision inspection machine.

[0021] Reference Figure 1 After the system starts running automatically, it will cycle through the following states until a stop command is received: standby, head cutting cycle, post-cutting conveyor connection, fixed length bonding cycle (including three fault tolerance mechanisms), fixed length cutting and short tail judgment, finished product output / short tail removal and baffle reset, return to standby (next piece).

[0022] This application also provides a cold shearing machine shearing control system based on vision and multi-sensor fusion, including the following steps: S1: Automatic head-cutting cycle.

[0023] The system scans the sensor combination signals in real time. When the following three conditions are met simultaneously, the cutting flag Q is automatically triggered, i.e., Q=1. Condition a: Material detection B, C, and D on the output roller conveyor of the cooling bed all detect rebar, ensuring that the entire steel bar has completely left the cooling bed; Condition b: Material detection A on the roller conveyor before cold shearing has no signal; Condition c: After cold shearing, the roller conveyor has no signal from the material detection A1. When Q=1, the system automatically starts the output roller conveyor of the cooling bed and the front roller conveyor of the cold shear, conveying the rebar forward to the blade of the cold shear machine.

[0024] Step S1 also includes S11 slow positioning and visual ranging: When the material detection A of the cold shear front roller conveyor detects a steel signal, the system automatically switches the speed of all currently running roller conveyors from "high-speed feeding" to "slow feeding speed" to ensure subsequent positioning accuracy; at this time, the camera S at the blade of the cold shear machine begins to collect images in real time, and identifies the end position of the rebar through the edge detection algorithm, and calculates the actual extension length L from the end to the shear blade.

[0025] Step S1 also includes S12 Single-blade shearing and cumulative allowance adaptive: The system has a built-in accumulator Sum_H with an initial value of 0: When the camera S detects that the extension length L is equal to Q2, the system immediately triggers the roller conveyor stop command and simultaneously sends a single shearing action command to the cold shear machine to complete the current blade shearing; After the cutting is completed, the accumulator is updated: Sum_H = Sum_H + Q2; the system performs a margin judgment: calculates the remaining cutting length Rem_H = Q1 – Sum_H; if Rem_H ≥ Q2, the above steps continue to be repeated; if Rem_H < Q2 and Rem_H > 0, the system automatically sets the target cutting length of the last cut to Rem_H, and triggers the last cutting when the camera S detects L = Rem_H to avoid overcutting; when the accumulated cutting length Sum_H = Q1, it indicates that all irregular segments of the head have been removed, the system automatically resets the cutting head flag Q, and the cutting head cycle ends.

[0026] S2: Post-cutting conveyor connection.

[0027] After the head-cutting mark Q is reset, the system detects the signals from the material detection A1 on the cold shearing roller conveyor and the camera S1 at the fixed-length baffle: when A1 detects no material and S1 detects no rebar in the area below the baffle, the system automatically triggers the roller conveyor steel feeding command, starts the pre-shearing and post-shearing roller conveyors, and continues to convey the head-cut rebar backward into the fixed-length shearing area.

[0028] S3: Automatic length-fitting cycle; S31: End face fitting state monitoring: when the rebar is conveyed to the sizing baffle, the camera S1 continuously collects images of the baffle area, and intelligently identifies the fitting state between the end of the rebar and the vertical end face of the sizing baffle; S32: Fitting judgment and adaptive alignment impacting action The system has a built-in fitting retry counter Retry, with an initial value of 0 and a maximum allowable retry count of 2; Case A: If S1 detects that the end face is completely fitted with the baffle, the system directly sends out a "shear permission" signal, proceeds to step S4, and clears Retry to 0 at the same time; Case B: If S1 detects a gap or an inclined end face, the system executes the following logic: a. Retry=Retry+1; judge the value of Retry; If Retry≤2: The system automatically performs the fine adjustment alignment impacting action: trigger the roller table to retreat slowly until the end stops at a position 50mm away from the baffle end face; after a pause, trigger the roller table to advance slowly, so that the end impacts the baffle at a low speed; after the impact, S1 detects the fitting state again; if it is normal, turn to Case A; if it is still abnormal, return to the start of Case B to continue the next round of retry; If Retry≥3: The system determines that there is severe deformation or foreign matter at the end of this section of rebar, stops performing the alignment impacting action, and directly issues a "shear permission" command to allow the cold shear to perform shearing, and simultaneously triggers a "fitting abnormality alarm" signal to inform the operator that there may be a length deviation or end defect in this section of sizing, so as to facilitate subsequent sorting processing. After the shearing is completed, the system automatically clears Retry to 0 and restores the normal process.

[0029] S4: Sizing shearing and short tail judgment.

[0030] After S1 confirms that the fitting is normal, the system immediately triggers the cold shear to execute the sizing shearing command. After the shearing is completed, the system collects the post-shearing state in real time and performs short tail sizing judgment: The system calculates the remaining multiple length: Rem_L=L0-Q1-n×D; if Rem_L≥D, the normal process continues; if Rem_L<D and Rem_L>0, proceed to step S5.

[0031] S5: Automatic processing flow for short tail sizing.

[0032] When the system determines that the remaining length Rem_L<D and Rem_L>0, the short tail sizing processing mode is triggered: S51: Short tail sizing alarm and identification: the system triggers a "short tail sizing alarm" signal to remind the monitoring personnel that the tail material processing stage has been entered; S52: The baffle opens automatically, and the system automatically triggers the command to lift the fixed-length baffle, no longer performing the end face fitting action, thus avoiding invalid collisions between the short tail ruler and the baffle. S53: Short tail ruler conveyor. The system keeps the pre-shear roller conveyor and post-shear roller conveyor running, and directly conveys the short tail ruler to the downstream dedicated short ruler collection area via the post-shear roller conveyor. S54: Short tail ruler shearing. If the length of the short tail ruler exceeds the upper limit of the roller conveyor allowed by the equipment, the system can automatically trigger the cold shear machine to cut it into 2-3 sections for easy collection. If the short tail ruler is short, it can be directly conveyed to the short ruler collection tank without shearing. S55: Area Reset and Loop Restart. When camera S1 detects no threaded steel under the baffle and A1 detects no material, the system determines that all short tail gauges have been cleared, automatically resets the length counter n, turns off the short tail gauge alarm, and sends a "single multiple gauge has been processed" signal to the central control. The system returns to the standby state of step S1 and waits for the next multiple gauge to arrive.

[0033] S6: Finished product output and baffle reset.

[0034] After the cutting is completed, the system simultaneously detects that the length-fixed baffle is automatically raised; The system waits for the steel demand signal from the downstream process. When the steel demand signal is received, the system starts the shearing roller conveyor to completely transport the finished rebar to the downstream finished product collection area. When camera S1 detects that there is no rebar in the area below the baffle, the system automatically issues a command to lower the fixed-length baffle, causing the baffle to return to the working position. After the baffle is reset, the system automatically returns to step S3 and begins the next cut length shearing cycle until step S4 triggers the short tail judgment and proceeds to step S5.

[0035] The exception and switching logic in this application embodiment: Manual mode priority: When switching to manual mode, all automatic cycles are immediately paused and the system is independently controlled by the control panel for handling emergencies or equipment maintenance.

[0036] Safety interlock: In any shearing cycle, if the cold shear machine is overloaded, the hydraulic pressure is abnormal, or the camera S / S1 loses its image signal, the system will immediately trigger an emergency stop and alarm, cutting off all roller drive and shearing actions to ensure equipment and personnel safety.

[0037] Adhesion Abnormality Alarm Continuity: The "Adhesion Abnormality Alarm" signal triggered in step S3 is continuously displayed on the HMI until the operator manually confirms and resets it, ensuring that the abnormal section of finished product can be effectively traced and sorted.

[0038] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A shearing control system for a cold shear machine based on vision and multi-sensor fusion, characterized in that: The system includes a cooling bed output roller conveyor, a pre-cold shearing roller conveyor, a cold shearing machine, a post-cold shearing roller conveyor, a length-fixing baffle, an operating table, and a detection device assembly. The operating table includes a manual / automatic switch and a human-machine interface. The cooling bed output roller conveyor is equipped with material detection sensors B, C, and D; the pre-cold shearing roller conveyor is equipped with material detection sensor A; and the post-cold shearing roller conveyor is equipped with material detection sensor A1. A camera S is installed at the blade of the cold shearing machine, and a camera S1 is installed at the length-fixing baffle. The system's control module uses a PLC and an image processing industrial control computer.

2. The shearing control system for a cold shear machine based on vision and multi-sensor fusion as described in claim 1, characterized in that: The system includes manual and automatic modes. In manual mode, the selection is made via a switch on the control panel, and each device is controlled individually by buttons or joysticks on the control panel. The visual signals are only used for monitoring and display and do not participate in closed-loop control. In automatic mode, the operator needs to input the core process parameters through the human-machine interface before starting the machine: total length of the multiple-length cut L0, total length of the cold shear head cut Q1, single cut length of the head cut Q2, finished product length D, and minimum tail length discard threshold Tmin. After the parameters are entered, the system enters an automatic standby state, and all subsequent actions are automatically triggered and executed cyclically by the sensor signals of the vision inspection machine.

3. The shearing control system for a cold shear machine based on vision and multi-sensor fusion as described in claim 2, characterized in that: After the system starts running automatically, it will cycle through the following states until a stop command is received: standby, head cutting cycle, post-cutting conveyor connection, fixed length bonding cycle, fixed length cutting and short tail judgment, finished product output / short tail removal and baffle reset, and return to standby.

4. A shearing control method for a cold shear machine based on vision and multi-sensor fusion, characterized in that: Includes the following steps: S1: Automatic head-cutting cycle; S2: Post-cutting conveyor connection; S3: Automatic length-fitting cycle; S4: Fixed-length cutting and short tail judgment; S5: Automatic processing flow for short tail rulers; S6: Finished product output and baffle reset.

5. The shearing control method for a cold shear machine based on vision and multi-sensor fusion as described in claim 4, characterized in that: In step S1: The system scans the sensor combination signals in real time. When the following three conditions are met simultaneously, the cutting flag Q is automatically triggered, i.e., Q=1. Condition a: Material detection B, C, and D on the output roller conveyor of the cooling bed all detect rebar, ensuring that the entire steel bar has completely left the cooling bed; Condition b: Material detection A on the roller conveyor before cold shearing has no signal; Condition c: After cold shearing, the roller conveyor has no signal from the material detection A1. When Q=1, the system automatically starts the output roller conveyor of the cooling bed and the roller conveyor before the cold shear, conveying the rebar forward to the blade of the cold shear machine; step S1 also includes slow positioning and visual ranging: when the material detection A of the roller conveyor before the cold shear detects a signal of steel, the system automatically switches the speed of all currently running rollers from "high-speed feeding" to "slow feeding speed" to ensure subsequent positioning accuracy; at this time, the camera S at the blade of the cold shear machine begins to collect images in real time, and identifies the end position of the rebar through the edge detection algorithm, and calculates the actual extension length L from the end to the shear blade; Step S1 also includes single-blade shearing and cumulative allowance adaptive: the system has a built-in accumulator Sum_H with an initial value of 0: when the camera S detects that the extension length L is equal to Q2, the system immediately triggers the roller conveyor stop command and simultaneously sends a single shearing action command to the cold shear machine to complete the current blade shearing; After the cutting is completed, the accumulator is updated: Sum_H = Sum_H + Q2; the system performs a margin judgment: calculates the remaining cutting length Rem_H = Q1 – Sum_H; if Rem_H ≥ Q2, the above steps continue to be repeated; if Rem_H < Q2 and Rem_H > 0, the system automatically sets the target cutting length of the last cut to Rem_H, and triggers the last cutting when the camera S detects L = Rem_H to avoid overcutting; when the accumulated cutting length Sum_H = Q1, it indicates that all irregular segments of the head have been removed, the system automatically resets the cutting head flag Q, and the cutting head cycle ends.

6. The shearing control method for a cold shear machine based on vision and multi-sensor fusion as described in claim 5, characterized in that: In step S2: After the head-cutting mark Q is reset, the system detects the signals from the material detection A1 on the cold shearing roller conveyor and the camera S1 at the fixed-length baffle: when A1 detects no material and S1 detects no rebar in the area below the baffle, the system automatically triggers the roller conveyor steel feeding command, starts the pre-shearing and post-shearing roller conveyors, and continues to convey the head-cut rebar backward into the fixed-length shearing area.

7. The shearing control method for a cold shear machine based on vision and multi-sensor fusion according to claim 6, characterized in that: In step S3: S31: End face fit status monitoring. When the rebar is conveyed to the fixed length baffle, the camera S1 continuously collects images of the baffle area and intelligently identifies the fit status between the end of the rebar and the vertical end face of the fixed length baffle. S32: Fitting determination based on adaptive alignment action The system has a built-in bonding retry counter, Retry, with an initial value of 0 and a maximum allowed number of retries of 2. Case A: If S1 detects that the end face is completely in contact with the baffle, the system directly issues a "cutting allowed" signal, proceeds to step S4, and clears Retry to zero. Case B: If S1 detects a gap or end face tilt, the system executes the following logic: a. Retry = Retry + 1; determine the value of Retry; If Retry≤2: The system automatically performs fine-tuning and alignment action: the roller conveyor is triggered to retreat slowly until the end retreats to 50mm from the end face of the baffle and stops; after the pause, the roller conveyor is triggered to advance slowly, so that the end hits the baffle at low speed; after the impact, S1 checks the bonding status again; if it is normal, it goes to situation A; if it is still abnormal, it returns to the beginning of situation B and continues the next round of retry. If Retry≥3: The system determines that there is severe deformation or foreign objects at the end of the rebar section, and will no longer continue to perform the alignment action. Instead, it will directly issue a "permit shearing" command, allowing the cold shearing machine to perform shearing. At the same time, it will trigger a "fitting abnormality alarm" signal to inform the operator that there may be a length deviation or end defect in the fixed length of the section, which will facilitate subsequent sorting. After shearing is completed, the system will automatically clear Retry to zero and restore the normal process.

8. The shearing control method for a cold shear machine based on vision and multi-sensor fusion according to claim 7, characterized in that: In step S4: Once S1 confirms that the fit is normal, the system immediately triggers the cold shear machine to execute the fixed-length shearing command. After shearing is completed, the system collects the post-shear status in real time and performs a short tail length determination. The system calculates the remaining multiple length: Rem_L = L0 - Q1 - n × D; if Rem_L ≥ D, then continue the normal process; if Rem_L < D and Rem_L > 0, then proceed to step S5.

9. The shearing control method for a cold shear machine based on vision and multi-sensor fusion as described in claim 8, characterized in that: In step S5: When the system determines that the remaining length Rem_L is less than D and Rem_L is greater than 0, the short tail ruler processing mode is triggered: S51: Short tail ruler alarm and identification, the system triggers the "short tail ruler alarm" signal to remind the monitoring personnel that the tail material processing stage is currently entered; S52: The baffle is automatically opened, the system automatically triggers the fixed-length baffle lifting command, no longer performs the end face fitting action, so as to avoid invalid collision between the short tail ruler and the baffle; S53: Short tail ruler conveying, the system keeps the pre-shear roller table and the post-shear roller table running continuously, and directly conveys the short tail ruler to the downstream special short ruler collection area through the post-shear roller table; S54: Short tail ruler shearing, if the length of the short tail ruler exceeds the upper limit of roller table conveying permitted by the equipment, the system can automatically trigger the cold shearing machine to cut it into 2-3 sections for easy collection; if the short tail ruler is relatively short, it can be directly conveyed to the short ruler collecting tank without shearing; S55: Area reset and cycle restart, when the camera S1 detects that there is no rebar under the baffle and A1 detects no material, the system determines that all short tail rulers have been completely removed, automatically resets the fixed-length counter n, turns off the short tail ruler alarm, and sends the signal "all single multiple-length pieces have been processed" to the central control, the system returns to the standby state of step S1 to wait for the arrival of the next multiple-length piece.

10. The shearing control method for a cold shear machine based on vision and multi-sensor fusion according to claim 9, characterized in that: In the described step S6: After the shearing is completed, the system simultaneously detects that the fixed-length baffle is automatically lifted; The system waits for the steel demand signal sent by the downstream process, and when receiving the steel demand signal, the system starts the post-shear roller table to completely convey the finished rebar to the downstream finished product collection area; When the camera S1 detects that there is no rebar in the area below the baffle, the system automatically issues a fixed-length baffle lowering command to reset the baffle to the working position; After the baffle is reset, the system automatically returns to step S3 to start the next fixed-length shearing cycle, until step S4 triggers the short tail judgment and proceeds to step S5.

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