Pixel array stack molding and two-dimensional to linear batch transport system and method

Abstract

The application discloses a pixel array laminating forming and two-dimensional to linear batch conveying system and method, and relates to the technical field of pixel handicraft production equipment. The system comprises an image processing module, a plate body assembly, a particle taking-out mechanism, a linear flow guide channel and a particle filling mechanism. The image processing module converts a target digital image into a pixel coordinate set and generates a color separation point coordinate set; the plate body assembly is provided with array-arranged particle limiting cavities, and the cavities have circumferential side walls to constrain the scattered particles into a two-dimensional ordered array; the particle taking-out mechanism sequentially takes out the particles according to the preset order of the cavity array and maintains the relative position relationship; the linear flow guide channel is adapted to the size of a single particle in shape, and the particles are sequentially arranged in a single column in the channel; and the particle filling mechanism fills the particles into the corresponding cavities according to the color separation point coordinate set to complete the two-dimensional pixel particle array forming. The application realizes complete dimension reduction conversion of the particles from a two-dimensional ordered array to a one-dimensional linear ordered sequence, is compatible with multiple taking-out modes such as bottom opening and closing gravity feeding and vacuum adsorption taking-out, supports synchronous batch filling and overall output of multiple laminated plates, and solves the problems of low pixel particle array forming efficiency and difficulty in directly converting a two-dimensional array into a one-dimensional linear sequence in the prior art.

Description

Technical Field

[0001] This invention relates to the field of pixel craft production equipment technology, specifically to a pixel array stacking molding and two-dimensional to linear batch conveying system and method, applicable to production scenarios such as pixel bead curtains, perforated bead patterns, mosaic tiles, etc., discrete particles are formed into pixel arrays and mass-produced, single-board or multi-layer boards are filled in monochrome batches, and two-dimensional arrays are transformed into one-dimensional linear ordered particle sequences. Background Technology

[0002] The production of pixelated crafts can be divided into two main categories: purely manual production and automated point-and-point equipment.

[0003] Purely manual production relies entirely on placing each piece individually or stringing them together row by row by hand. The pattern forming cycle is long, the consistency is poor, and the labor cost is extremely high, making it difficult to achieve mass production.

[0004] Existing automated equipment mostly adopts a three-axis motion head, robotic arm, and 3D printing-style point-to-point material dropping structure, all of which are point-to-point interlacing placement modes, making it impossible to achieve batch production of the whole board with the same color, resulting in extremely low production efficiency.

[0005] The existing technology has the following core defects: Traditional automated equipment cannot achieve batch filling of all points of the same color at one time, and requires frequent positioning and color changing, resulting in extremely low mass production efficiency. The formed particles are mostly in a planar scattered state, without regular array constraints. It is impossible to directly convert the complete two-dimensional pixel array into a one-dimensional linear ordered particle sequence. It must be manually sorted and arranged again, which is a cumbersome process. The traditional grooved plate with a closed bottom structure hinders vertical material feeding, making it impossible to stack and use multiple layers of plates simultaneously, severely limiting production capacity. The planar open-type ball bearing process has no sidewall limit, and the particles roll freely, misalign, and mix colors when the material is poured out. To ensure the yield, the speed must be reduced. Speed ​​and precision cannot be achieved at the same time, making it unsuitable for large-scale mass production. Summary of the Invention

[0006] This invention aims to overcome the shortcomings of the prior art and provide a pixel array stacking and two-dimensional to linear batch transport system and method.

[0007] The core concept of this invention lies in using an array cavity with sidewalls to fix physical particles into a two-dimensional ordered array, with the sorting function completed by the cavity array itself. Subsequently, a particle extraction mechanism extracts the particles one by one according to a preset order of the cavity array. After extraction, each particle maintains its original relative order and enters a linear flow channel. The linear flow channel only performs the function of single-column ordered transport, ultimately converting the entire two-dimensional pixel array into a one-dimensional linearly ordered particle sequence for output. The particle extraction mechanism is not limited to specific directions or forces such as bottom opening and closing, gravity falling, or downward flow; any method that can extract particles in sequence and output them in order falls within the protection scope of this invention.

[0008] This invention provides a pixel array stacking and two-dimensional to linear batch conveying system, including: an image processing module, a plate assembly, a particle removal mechanism, a linear flow channel, and a particle filling mechanism.

[0009] The image processing module is used to receive the target digital image, convert the image into a pixel image of a preset resolution, establish a one-to-one mapping relationship between the image pixel coordinates and the physical coordinates of the particle limiting cavity on the board assembly, and split and generate a set of color separation point coordinates according to the pixel color type.

[0010] The plate assembly comprises at least one plate, each plate having an array of particle-limiting cavities. Each particle-limiting cavity has four side walls, and its internal dimensions are adapted to the external dimensions of a single physical particle to be processed. Each cavity accommodates only a single physical particle, ensuring stable positioning of the particle within the cavity and forming a regular two-dimensional pixel particle array. When the plate assembly is arranged in multiple layers, the particle-limiting cavities on each plate are vertically connected through holes. After stacking, the corresponding through holes are perfectly aligned, forming a continuous vertical feeding channel that runs through all the stacked plates.

[0011] The particle removal mechanism is used to remove physical particles from each particle-limiting cavity according to a preset order of the cavity array. During removal, each particle maintains the same relative positional relationship as the cavity array, and the removed particles are sequentially fed into the linear guide channel. The particle removal mechanism can be a bottom-opening and closing removal mechanism, which controls the closing and opening of the bottom discharge port of each particle-limiting cavity to achieve gravity-induced particle descent; or it can be a vacuum adsorption removal mechanism, which picks up particles from the top or side of the plate assembly according to a preset order of the cavity array and releases them sequentially into the linear guide channel.

[0012] The cross-sectional dimensions of the linear flow channel are adapted to the external dimensions of individual physical particles, allowing only a single particle to pass through in a single row along the channel's axial direction. The linear flow channel can be a transitional component independently located below the plate assembly, or a conduit or pipe connected below each extraction position, or an array of guide grooves, or other structural forms capable of applying single-row guiding constraints to individual particles. The linear flow channel is adapted to the position below the bottom discharge port of the particle limiting opening and closing mechanism, or to the release position of the vacuum adsorption extraction mechanism. Particles are arranged sequentially within the channel according to the extraction order, forming a one-dimensional linear ordered sequence.

[0013] The particle filling mechanism is used to fill physical particles into the corresponding particle-limiting cavities on the board assembly according to the color-separation point coordinate set, so that each cavity forms a two-dimensional pixel particle array according to the target pattern. The particle filling mechanism can be a whole-board global filling mechanism, a point-by-point filling mechanism, or a multi-axis motion filling mechanism. The particle filling mechanism can also be used in conjunction with a point selection isolation component. The point selection isolation component is used to selectively open or close the points of the board cavity according to the color-separation point coordinate set, so that all cavity points of the current target color are open and cavity points of non-target colors are closed, so as to achieve uniform filling of the whole board with the same color.

[0014] When a complete two-dimensional pixel particle array has been formed in the limiting cavity of each particle on the plate assembly, the particle removal mechanism will remove all the particles in sequence according to the preset order of the cavity array and send them into the corresponding linear guide channel. The particles maintain the removal order in the channel, and the overall conversion and output of the two-dimensional particle array into a one-dimensional linear ordered particle sequence is completed in one go.

[0015] Furthermore, the multi-layer laminated board assembly is an integral locking structure, with each laminated board having a matching alignment structure. After stacking, the through holes at corresponding positions of each board remain vertically coaxial. The board assembly also includes a locking mechanism that locks all laminated boards together as one unit. Each laminated board synchronously performs full-area filling of the same color and forms a multi-layer consistent two-dimensional pixel particle array.

[0016] The present invention also provides a method for pixel array stacking and two-dimensional to linear batch transport using the above system, comprising the following steps: (1) Establish a one-to-one mapping between image pixel coordinates and particle limiting cavity physical coordinates, and generate a set of color separation point coordinates by splitting by color; (2) Assemble the plate components. In the single-layer mode, select the independently formed plate. In the multi-layer mode, align the plates with each through hole and lock them together. (3) The particle filling mechanism fills the physical particles into the corresponding particle limiting cavity on the plate assembly according to the color separation point coordinate set, so that each cavity forms a two-dimensional pixel particle array according to the target pattern. (4) The particle removal mechanism removes the physical particles in each particle-limiting cavity in sequence according to the preset order of the cavity array. After removal, each particle enters the linear guide channel in a relative order. (5) Each particle is arranged in the order of extraction in the corresponding linear guide channel, and the overall conversion and output of the two-dimensional array into multiple one-dimensional linear ordered particle sequences is completed in one go.

[0017] Furthermore, in step (4), the particle removal mechanism can adopt a bottom opening and closing method, that is, the particle limiting opening and closing mechanism is opened, and all particles fall synchronously under gravity in the vertical direction and enter the linear guide channel corresponding to each discharge port.

[0018] Furthermore, in step (3), all cavity points of the current target color can be connected and the remaining points can be blocked by the point selection isolation component. The particle filling mechanism performs particle filling of the current color on the connected points. The color is switched sequentially and the operation is repeated until the complete two-dimensional pixel particle array is formed. In the multi-layer stacked plate mode, the corresponding target color points of each stacked plate are connected and filled synchronously, and finally a multi-layer consistent two-dimensional pixel particle array is formed. Detailed Implementation

[0019] Example 1: Bottom opening and closing gravity descent combined with the lower linear guide channel In this embodiment, the particle extraction mechanism adopts a particle limiting opening and closing mechanism. The plate assembly is a single-layer independently molded plate with an array of particle limiting cavities arranged on it. The cavities are through holes running vertically and have closed sidewalls around them. The internal dimensions of the cavities are adapted to the external dimensions of a single physical particle. A linear flow channel is provided below the plate. The channel is an independent connecting component. The upper end of the channel has receiving holes corresponding to each discharge port. Multiple independent single-row flow channels corresponding to each discharge port are opened inside the channel. The cross-sectional dimensions of the channel only allow a single particle to pass through in a single row along the axial direction.

[0020] During production, the image processing module imports the target digital pattern, establishes a one-to-one mapping between image pixel coordinates and cavity physical coordinates, and generates a set of color-separated point coordinates by color. The particle filling mechanism adopts a multi-axis motion filling mechanism, which sequentially delivers individual particles to the corresponding cavities according to the color-separated point coordinate set, ultimately forming a complete two-dimensional pixel particle array.

[0021] After the entire plate is formed, the particle limiting opening and closing mechanism is activated, all discharge ports open simultaneously, and all particles fall synchronously under gravity in the vertical direction, entering the corresponding linear guide channels below. They are arranged in order of falling in the channels, completing the overall conversion and output of the two-dimensional array into multiple one-dimensional linear ordered sequences in one go.

[0022] Example 2: Sequential removal of samples using vacuum adsorption above, combined with a linear flow guiding channel. In this embodiment, the particle removal mechanism is a vacuum adsorption removal mechanism. The plate assembly is the same as in Embodiment 1, and the particles form a two-dimensional ordered array within the cavity. The particle removal mechanism includes multiple rows of vacuum nozzles, with the nozzle array corresponding to the column direction of the cavity array, allowing for the suction of particles column by column along the column direction.

[0023] During production, once a complete two-dimensional pixel particle array is formed within the cavity, the vacuum adsorption extraction mechanism sequentially picks up the particles from above the plate, column by column, in the same order as the column sequence of the cavity array. Within each column, the particles are sequentially drawn into the suction nozzle in row-by-row order. The nozzle then releases the picked-up particles sequentially into a linear flow channel. This channel is adapted to the release position of the vacuum adsorption extraction mechanism, ensuring the particles remain arranged in a single column within the channel, thus completing the overall conversion from a two-dimensional array to a one-dimensional linearly ordered sequence.

[0024] This embodiment illustrates that the sorting function is performed by the cavity array, and the extraction direction is not limited; even when extracted from above, the sample falls within the protection range.

[0025] Example 3: Multi-layer stacked plate rivet selection, full-area batch filling, and bottom opening / closing output. This embodiment employs a ten-layer stack of through-hole plates, each plate having alignment pin holes. After stacking, the plates are locked together as a single unit using a locking mechanism. All through holes are initially sealed with rivets. After the image processing module generates a set of color-separated point coordinates, it retrieves all rivets corresponding to each monochrome point, ensuring vertical channels are open for all pixels of that color, while keeping the remaining points sealed. A vibration filling mechanism is used to fill the entire plate, with particles falling into the cavity only through the open points, completing the full-area filling of the current color. This process is repeated with each color, until all ten layers synchronously form a completely identical two-dimensional pixel particle array.

[0026] After molding, the bottom isolation plate is removed using a bottom-opening and closing mechanism. All particles fall synchronously by gravity along the vertical through-channel and enter the corresponding linear guide channels below, where they are arranged in a single row for output. This embodiment uses ten layers as an example, but the actual number of layers can be adjusted.

[0027] Example 4: Laser-drilled template with full-area masking and selective batch forming This embodiment uses a laser-drilled template as a point selection and isolation component, adaptable to single-layer or multi-layer laminated boards. After the image processing module outputs the color point coordinate set, the laser processing mechanism cuts an array of through holes corresponding to the monochrome points on the template. The template is attached to the upper surface of the board, only conducting the target color points, while the remaining points are obscured by the template. A vibration filling mechanism is used to fill the entire board, with particles falling into the target cavity only through the template through holes, completing the full-area filling of the current color. The template is replaced color by color until a complete two-dimensional pixel particle array is formed.

[0028] After molding, the particle removal mechanism can sequentially remove the particles according to the bottom opening and closing method of Example 1 or the top vacuum adsorption method of Example 2, and output them in a single row through the linear guide channel.

[0029] Comparison with existing technology descriptions Compared to the point-by-point process of robotic arms: existing technologies involve intermittent color changing at each point, resulting in extremely low efficiency. This invention is compatible with both point-by-point fixed-point filling and full-area batch filling of the entire board, and it is the first to create a multi-layer stacked board integrated synchronous single-color batch filling process, achieving one-time molding of the same color, which greatly improves mass production efficiency. Compared to the planar tilting process, where there are no sidewall constraints and beads roll and mix colors, this invention relies on the sidewall constraints of the cavity to constrain the particle posture throughout the process. The sorting is completed by the cavity array, and after being removed, the particles maintain their order and enter the linear guide channel, without misalignment or mixing.

[0030] Compared to traditional single-layer board processes, this invention pioneers a multi-layer integrated synchronous molding process, enabling simultaneous production of multiple boards and significantly increasing production capacity. Furthermore, the particle removal mechanism is not limited to a specific removal direction; bottom opening and closing, top adsorption, and lateral ejection can all achieve the overall conversion and output of a two-dimensional array into a one-dimensional linear ordered sequence.

[0031] This invention forms a complete process link by pixel coordinate mapping, cavity array limiting and sorting, arbitrary sequential extraction, and linear current guiding and order-preserving output, taking into account accuracy, yield and mass production speed.

Claims

1. A pixel array stacking and two-dimensional to linear batch conveying system, characterized in that, include: Image processing module, board assembly, particle removal mechanism, linear flow channel and particle filling mechanism; The image processing module is used to receive the target digital image, convert the image into a pixel image with a preset resolution, establish a one-to-one mapping relationship between the image pixel coordinates and the physical coordinates of the particle limiting cavity on the plate assembly, and split and generate a set of color separation point coordinates according to the pixel color type. The plate assembly includes at least one plate, and each plate is provided with an array of particle limiting cavities. The particle limiting cavities have four side walls, and the inner cavity size is adapted to the outer size of a single physical particle to be processed. When the plate assembly is arranged in multiple layers, the particle limiting cavities on each plate are through holes that run vertically through each other. After stacking, the through holes at corresponding positions are completely aligned to form a continuous vertical material feeding channel that runs through all the stacked plates. The particle removal mechanism is used to remove the physical particles in each particle limiting cavity according to the preset order of the cavity array. During removal, each particle maintains the same relative positional relationship as the cavity array, and the removed particles are sequentially sent into the linear guide channel. The cross-sectional dimensions of the linear flow channel are adapted to the external dimensions of a single physical particle, allowing only a single particle to pass through in a single row along the channel axis; the particles are arranged sequentially in the channel according to the order in which they were removed, forming a one-dimensional linear ordered sequence. The particle filling mechanism is used to fill physical particles into the corresponding particle limiting cavity on the plate assembly according to the color separation point coordinate set, so that each cavity forms a two-dimensional pixel particle array according to the target pattern. When a complete two-dimensional pixel particle array has been formed in the limiting cavity of each particle on the plate assembly, the particle extraction mechanism will extract all the particles in sequence according to the preset order of the cavity array and send them into the corresponding linear guide channel, thus completing the overall conversion and output of the two-dimensional particle array into a one-dimensional linear ordered particle sequence in one go.

2. The system according to claim 1, characterized in that, It also includes a point selection isolation component, which is used to selectively open or block the cavity points of the board body according to the coordinate set of the color point, so that all cavity points of the current target color are open and cavity points of non-target colors are blocked, so as to achieve uniform filling of the whole board with the same color; the point selection isolation component is a detachable single-point blocking component or an integral selection template.

3. The system according to claim 1, characterized in that, The particle removal mechanism includes a particle limiting opening and closing mechanism, which controls the closing and opening of the discharge port at the bottom of each particle limiting cavity; when the discharge port is open, the particles fall vertically by gravity and enter the linear guide channel located below the discharge port and corresponding to the discharge port one by one.

4. The system according to claim 1, characterized in that, The particle removal mechanism includes a vacuum adsorption removal mechanism, which picks up particles from above or to the side of the plate assembly in a preset order of the cavity array and releases the picked-up particles sequentially into the linear guide channel.

5. The system according to claim 3 or 4, characterized in that, The linear flow channel is a connecting component independently set below the plate assembly, or a conduit or pipe connected below each extraction position, or a guide groove array, or other structural form capable of applying a single-row guiding constraint to a single particle; the linear flow channel is adapted to the position below the bottom discharge port of the particle limiting opening and closing mechanism, or adapted to the release position of the vacuum adsorption extraction mechanism.

6. The system according to claim 1, characterized in that, The particle filling mechanism can be a whole-plate full-area filling mechanism, which performs whole-plate filling on all cavity points that are connected to the current target color at one time; or a point-by-point filling mechanism, which performs particle laying on cavity points that are connected to the current target color one by one; or a multi-axis motion filling mechanism, which transports single particles to each corresponding cavity point in sequence through a motion platform.

7. The system according to claim 1, characterized in that, The multi-layer laminated board assembly is an integral locking structure. Each laminated board has a matching structure that works together. After stacking, the through holes at corresponding positions of each board are kept vertically coaxial. The board assembly also includes a locking mechanism that locks all laminated boards together. Each laminated board performs full-area filling of the same color synchronously and forms a multi-layer consistent two-dimensional pixel particle array.

8. A method for pixel array stacking and two-dimensional to linear batch transport using the system described in any one of claims 1 to 7, characterized in that, Includes the following steps: (1) Establish a one-to-one mapping between image pixel coordinates and particle limiting cavity physical coordinates, and generate a set of color separation point coordinates by splitting by color; (2) Assemble the plate components. In the single-layer mode, select the independently formed plate. In the multi-layer mode, align the plates with each through hole and lock them together. (3) The particle filling mechanism fills the physical particles into the corresponding particle limiting cavity on the plate assembly according to the color separation point coordinate set, so that each cavity forms a two-dimensional pixel particle array according to the target pattern. (4) The particle removal mechanism removes the physical particles in each particle-limiting cavity in sequence according to the preset order of the cavity array. After removal, each particle enters the linear guide channel in a relative order. (5) Each particle is arranged in the order of extraction in the corresponding linear guide channel, and the overall conversion and output of the two-dimensional array into multiple one-dimensional linear ordered particle sequences is completed in one go.

9. The method according to claim 8, characterized in that, In step (4), the particle removal mechanism adopts a bottom opening and closing method: when the particle limiting opening and closing mechanism is opened, all particles fall synchronously under gravity in the vertical direction and enter the linear guide channel corresponding to each discharge port.

10. The method according to claim 8, characterized in that, In step (3), all cavity points of the current target color are connected and the remaining points are blocked by the point selection isolation component. The particle filling mechanism performs particle filling of the current color on the connected points. The operation is repeated by switching colors in sequence until a complete two-dimensional pixel particle array is formed. In the multi-layer stacking mode, the corresponding target color points of each stacked board are synchronously connected and synchronously filled, ultimately forming a multi-layer consistent two-dimensional pixel particle array.