System for automatically controlling fragments to fall into plate in photovoltaic glass transmission process

Abstract

An automatic control system for fragment falling in the photovoltaic glass conveying process comprises a glass defect online detection system used for recognizing glass defects on a conveying roller way, the conveying roller way is connected with an inlet of a falling table in the flowing direction of glass, and a photoelectric sensor is arranged at the inlet of the falling table. The digital signal output end of the photoelectric sensor is connected with the digital signal input end of the PLC, the digital signal output end of the glass defect online detection system is connected with the digital signal input end of the PLC, the PLC is in signal connection with the electromagnetic valve, and the electromagnetic valve is arranged in a pipeline through which the air cylinder on the sheet falling table is communicated with the air storage tank; a glass defect signal identified by the glass defect online detection system and a glass position signal detected by the photoelectric sensor are synchronously transmitted to the PLC, and the PLC controls the electromagnetic valve to further control the roller on the sheet falling table to turn over, so that the defective glass falls off.

Description

Technical Field

[0001] The utility model relates to the technical field of automatic control of photovoltaic glass deep processing, in particular to an automatic control system for falling pieces of photovoltaic glass during its transmission process. Background Art

[0002] Every step in the photovoltaic glass production process is crucial, especially the quality of the glass substrate, which directly impacts the performance and yield of the final product. During the initial production stages of photovoltaic glass, inherent defects such as calculi, bubbles, and microcracks may develop due to various factors, including impure raw materials, uneven melting, and improper cooling control. These defects may not be noticeable during the glass's molding process, but once the glass enters the tempering stage, the rapid temperature fluctuations and uneven stress distribution magnify these potential problems, significantly increasing the glass's fragility during transportation.

[0003] While tempered photovoltaic glass boasts improved strength and thermal shock resistance, internal defects can become a critical weakness. On high-speed production lines, even tiny fragments that fail to fall from the conveyor belt and reach the collection hopper in time can cause further damage due to the impact of subsequent glass, triggering a chain reaction. This can not only cause glass fragments to collide on the conveyor rollers, increasing the risk of surface scratches, but can also cause the accumulation of fragments to block the production line, causing interruptions and severely impacting production efficiency and product yield.

[0004] Traditional manual handling methods are insufficient to meet this challenge. Manual cleaning is not only inefficient and unable to keep up with the high-speed production line, but is also prone to exacerbating problems due to operator errors or delayed response. Furthermore, prolonged and intensive work poses a threat to worker safety and health. Therefore, finding an automated, efficient, and precise debris handling solution is crucial to improving the quality of photovoltaic glass production and ensuring production continuity.

[0005] Utility model patent application publication number CN 203133000U discloses an image-based online glass defect detection device, comprising an image acquisition unit, an image processing unit, and a result display unit, connected in sequence. The device is used to identify defects such as glass bubbles and cracks, improving the inspection accuracy and production efficiency of glass products. However, the device is only designed to identify broken glass and has not been integrated into an actual production line to achieve the desired effect of identifying and automatically separating broken glass. Its practicality needs further improvement. Summary of the Invention

[0006] In order to overcome the deficiencies of the above-mentioned prior art, the purpose of the present utility model is to provide an automatic control system for the falling of fragments during the transmission of photovoltaic glass. A photoelectric sensor is added to the existing online glass defect detection system, and the original belt transmission on the drop-off table is changed to multiple rollers for transmission, so that the glass defect signal identified by the online glass defect detection system and the glass position signal detected by the photoelectric sensor are synchronously transmitted to the PLC controller. The PLC controller further controls the flipping of the rollers on the drop-off table by controlling the solenoid valve to realize the falling of defective glass. This process adopts synchronous detection and does not require manual intervention, which has the advantages of energy saving and consumption reduction, improving yield rate, equipment utilization rate, and saving labor costs.

[0007] In order to achieve the above purpose, the technical solution adopted by the utility model is:

[0008] An automatic control system for falling glass fragments during the transmission process of photovoltaic glass includes a glass defect online detection system 2 for identifying glass defects on a transmission roller 6. The transmission roller 6 is connected to the entrance of a sheet dropping platform 1 along the flow direction of the glass. A photoelectric sensor 7 is provided at the entrance of the sheet dropping platform 1. The digital signal output end of the photoelectric sensor 7 is connected to the digital signal input end of a PLC controller 3. The digital signal output end of the glass defect online detection system 2 is connected to the digital signal input end of the PLC controller 3. The PLC controller 3 is connected to a solenoid valve 4 in a signal connection. The solenoid valve 4 is arranged in a pipeline connecting a cylinder 5 on the sheet dropping platform 1 and a gas storage tank 8.

[0009] Furthermore, the sheet dropping table 1 is provided with a crank connecting rod 13 connected to the piston rod 12 of the cylinder 5, the crank connecting rod 13 is connected to the base 14, a plurality of rollers 16 are provided on the base 14 through a bearing seat 15, a pulley 17 and a plurality of rollers 18 are provided on the roller 16, the pulleys 17 are connected to each other through an O-belt 11, the roller 16 is connected to the power output end of the reducer 19 through a stepped shaft 20, the power input end of the reducer 19 is connected to the power output end of the motor 10, and the signal input end of the motor 10 is connected to the signal output end of the PLC controller 3 through the frequency converter 9.

[0010] Furthermore, the glass defect online detection system 2 includes an image acquisition unit 21 and an image processing unit 22 connected in sequence; the image acquisition unit 21 includes a light source 210 and a CCD12 camera 211, and the light source 210 and the CCD12 camera 211 are located on both sides of the glass panel to be inspected; the image processing unit 22 includes an image acquisition card 220, a DSP image processing module 221 and a signal conversion module 222 connected in sequence; the signal output end of the CCD12 camera 211 is connected to the signal input end of the image acquisition card 220, the signal output end of the image acquisition card 220 is connected to the signal input end of the DSP image processing module 221, the signal output end of the DSP image processing module 221 is connected to the signal input end of the signal conversion module 222, and the signal output end of the signal conversion module 222 is connected to the signal input end of the PLC controller 3.

[0011] Furthermore, a glass hopper 23 is provided below the sheet dropping platform 1 .

[0012] Furthermore, the rollers 16 are arranged in parallel.

[0013] Furthermore, the roller 16 is provided with a pulley 17 and two rollers 18 .

[0014] Compared with the prior art, the present invention has the following beneficial effects:

[0015] 1. The utility model replaces the original belt transmission on the sheet dropping platform 1 with a plurality of rollers 16 for transmission. Cylinders 5 are installed on both sides of the sheet dropping platform 1. The cylinders 5 drive the crank connecting rod 13 to swing, the crank connecting rod 13 drives the base 14 to rotate, and the base 14 drives the plurality of rollers 16 to flip and open at 90 degrees to the ground, thereby achieving the dropping of defective glass. This process does not require manual intervention and has the advantages of improving production efficiency, ensuring product quality, reducing labor costs and improving safety.

[0016] 2. The present invention adds a photoelectric sensor 7 to the existing glass defect online detection system 2 to detect the position signal of the defective glass when it arrives at the entrance of the drop table 1; there will be a short detection reaction time when the glass to be detected flows through the glass defect online detection system 2. Combined with the position signal detected by the photoelectric sensor 7, the falling of the defective glass on the drop table can be more accurately controlled; the synchronous detection method is adopted to ensure the accuracy and timeliness of the detection, thereby better improving the detection accuracy, optimizing production efficiency and improving the level of automation.

[0017] In summary, the present invention adds a photoelectric sensor 7 to the existing glass defect online detection system 2, and changes the original belt transmission on the drop table 1 to multiple rollers 16 for transmission, thereby realizing the synchronous transmission of the glass defect signal identified by the glass defect online detection system 2 and the glass position signal detected by the photoelectric sensor 7 to the PLC controller 3. The PLC controller 3 further controls the flipping of the roller 16 on the drop table 1 by controlling the solenoid valve 4 to realize the falling of the defective glass; this process adopts synchronous detection and does not require manual intervention, which better improves the detection accuracy, has the advantages of energy saving and consumption reduction, improving the yield rate, equipment utilization rate, and saving labor costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a schematic diagram of the control process flow of the utility model;

[0019] Figure 2 This is a left-side structural schematic diagram of the sheet dropping platform 1 of the present invention;

[0020] Figure 3 This is a schematic diagram of the main structure of the sheet dropping platform 1 of the present invention;

[0021] Figure 4 This is a schematic diagram of the top view of the sheet dropping platform 1 of the present invention;

[0022] Figure 5 This is a structural diagram of the glass defect online detection system 2 of the present invention;

[0023] Figure 6 This is the control circuit schematic diagram of the PLC controller 3 of the present utility model;

[0024] Figure 7 This is a schematic diagram of the control circuit of the solenoid valve 4 of the present invention;

[0025] In the figure: 1. Sheet drop table; 2. Glass defect online detection system; 3. PLC controller; 4. Solenoid valve; 5. Cylinder; 6. Conveyor roller; 7. Photoelectric sensor; 8. Gas tank; 9. Frequency converter; 10. Motor; 11. O-belt; 12. Piston rod; 13. Crank connecting rod; 14. Base; 15. Bearing seat; 16. Roller; 17. Pulley; 18. Roller; 19. Reducer; 20. Step shaft; 21. Image acquisition unit; 22. Image processing unit; 210. Light source; 211. CCD12 camera; 220. Image acquisition card; 221. DSP image processing module; 222. Signal conversion module; 23. Glass hopper. DETAILED DESCRIPTION

[0026] The present invention will be described in further detail below with reference to the accompanying drawings.

[0027] See also Figure 1-5 , an automatic control system for falling panels of photovoltaic glass during transmission, including a glass defect online detection system 2 for identifying glass defects on a transmission roller 6, the transmission roller 6 is connected to the entrance of a sheet dropping platform 1 along the flow direction of the glass, a photoelectric sensor 7 is provided at the entrance of the sheet dropping platform 1, the digital signal output end of the photoelectric sensor 7 is connected to the digital signal input end of a PLC controller 3, the digital signal output end of the glass defect online detection system 2 is connected to the digital signal input end of the PLC controller 3, the PLC controller 3 is connected to the solenoid valve 4 in signal connection, and the solenoid valve 4 is arranged in a pipeline connecting a cylinder 5 on the sheet dropping platform 1 and a gas storage tank 8.

[0028] In this embodiment, a photoelectric sensor 7 is added to the existing glass defect online detection system 2 to detect the position signal of the defective glass when it arrives at the entrance of the drop table 1; there will be a short detection reaction time when the glass to be detected flows through the glass defect online detection system 2. Combined with the position signal detected by the photoelectric sensor 7, the falling of the defective glass on the drop table 1 can be more accurately controlled; the synchronous detection method is adopted to ensure the accuracy and timeliness of the detection, thereby better improving the detection accuracy, optimizing production efficiency and improving the level of automation.

[0029] like Figure 2 、 Figure 3 and Figure 4 As shown, the sheet dropping table 1 is provided with a crank connecting rod 13 connected to the piston rod 12 of the cylinder 5, the crank connecting rod 13 is connected to the base 14, a plurality of rollers 16 are provided on the base 14 through a bearing seat 15, a pulley 17 and a plurality of rollers 18 are provided on the roller 16, the pulleys 17 are connected by an O-belt 11, the roller 16 is connected to the power output end of the reducer 19 through a stepped shaft 20, the power input end of the reducer 19 is connected to the power output end of the motor 10, and the signal input end of the motor 10 is connected to the signal output end of the PLC controller 3 through the frequency converter 9.

[0030] In this embodiment, the original belt transmission on the sheet dropping platform 1 is replaced with a plurality of rollers 16 for transmission. Cylinders 5 are installed on both sides of the sheet dropping platform 1. The cylinders 5 drive the crank connecting rod 13 to swing, the crank connecting rod 13 drives the base 14 to rotate, and the base 14 drives the plurality of rollers 16 to flip and open at 90 degrees to the ground, thereby achieving the dropping of defective glass. This process does not require manual intervention and has the advantages of improving production efficiency, ensuring product quality, reducing labor costs and improving safety.

[0031] like Figure 3 As shown, a glass hopper 23 is provided below the sheet dropping platform 1 , and the glass hopper 23 is used to receive defective glass dropped from the sheet dropping platform 1 .

[0032] like Figure 4As shown, the rollers 16 are arranged in parallel.

[0033] like Figure 4 As shown, the roller 16 is provided with a pulley 17 and two rollers 18 .

[0034] like Figure 5 As shown, the online glass defect detection system 2 includes an image acquisition unit 21 and an image processing unit 22, which are connected in sequence. The image acquisition unit 21 includes a light source 210 and a CCD12 camera 211. The light source 210 and the CCD12 camera 211 are located on both sides of the glass panel to be inspected. The light source 210 evenly projects light onto the glass panel to be inspected. The CCD12 camera 211 collects information about the glass panel and outputs analog signals to the image processing unit 22.

[0035] The image processing unit 22 includes an image acquisition card 220, a DSP image processing module 221, and a signal conversion module 222, which are connected in sequence. The signal output of the CCD12 camera 211 is connected to the signal input of the image acquisition card 220, which is connected to the signal input of the DSP image processing module 221, which is connected to the signal input of the signal conversion module 222, which is connected to the signal input of the PLC controller 3.

[0036] The CCD12 camera 211 transmits the collected glass panel information to the image acquisition card 220, and the image acquisition card 220 transmits the collected data to the DSP image processing module 221. The DSP image processing module 221 further processes and recognizes the image, and then matches and transmits the recognition result to the PLC controller 3 through the signal conversion module 222.

[0037] The digital signal output terminal of the signal conversion module 222 of this embodiment is connected to the digital signal input terminal of the PLC controller 3, so as to obtain the detected glass defect signal and control the subsequent automatic dropping process of the defective glass.

[0038] Among them, the PLC controller 3 is implemented based on Siemens 6ES7214-1AG40-0XB0; the photoelectric sensor 7 is implemented based on Omron E3NX-CA11; the image acquisition card is implemented based on IEEE1394 image acquisition card; the DSP image processing module 221 is implemented based on TI's TMS320C6416; and the signal conversion module 222 is implemented based on FPGA chip.

[0039] like Figure 6 and Figure 7As shown, the glass fragmentation signal output by the online glass defect detection system 2 is connected to input terminal I0.1 of the PLC controller 3 input module via a signal line. The glass position signal detected by the photoelectric sensor 7 is also connected to input terminal I0.0 of the PLC controller 3 input module via a signal line. Output terminal Q0.0 of the PLC controller 3 output module is connected to one end of the KA1 wire package. The other end of the KA1 wire package is connected to the 0V power supply. The 24V power supply is connected to the normally open contact 1 of KA1. The normally open contact 2 of KA1 is connected to one end of the solenoid valve wire package. The 0V power supply is connected to the other end of the solenoid valve wire package, forming a complete automatic control loop. In manual mode, the 24V power supply is connected to contact 1 of the manual button SA1. Contact 2 of the manual button SA1 is connected to one end of the KA2 wire package. The other end of the KA2 wire package is connected to the 0V power supply. The 24V power supply is connected to normally open contact 1 of KA2. The normally open contact 2 of KA2 is connected to one end of the solenoid valve wire package. The 0V power supply is connected to the other end of the solenoid valve wire package, forming a complete manual control loop.

[0040] PLC controller 3 input terminals I0.1 and I0.0 receive glass defect signals from the online glass defect detection system 2 and glass position signals from the photoelectric sensor 7, respectively. PLC controller 3 output terminal Q0.0 activates or deactivates relay KA1, causing the coil of solenoid valve 4 to operate or deactivate in real time. When both input terminals I0.1 and I0.0 of PLC controller 3 are at logic 1, output terminal Q0.0 of the PLC controller 3 output module is set to 1, turning on relay KA1. This activates solenoid valve 4, causing rollers 16 of the drop table 1 to tilt 90 degrees from the center to the sides, allowing defective glass to automatically fall into hopper 23. In manual operation, button SA1 directly controls the opening and closing of the solenoid valve. Output terminal Q0.1 of the PLC controller 3 output module is the motor start / stop signal. When there is no debris signal, PLC controller 3 stops outputting the drop signal and issues a motor start signal. Solenoid valve 4 closes, and the rollers 16 of the drop table 1 are parallel to the ground. Motor 10 starts and operates in real time, allowing glass to be transported normally and connected to production.

[0041] The working principle of this utility model is:

[0042] The existing online glass defect detection system 2 is used to identify defective glass, and the added photoelectric sensor 7 detects the glass's position. When the glass reaches the drop table 1, the PLC controller 3 outputs a drop signal to the relay. Through signal isolation, the relay issues an instruction to open the solenoid valve 4. The solenoid valve 4 opens, and compressed air is delivered to the cylinder 5 of the drop table 1. The cylinder 5 drives the crank connecting rod 13 to swing, which in turn rotates the base 14. The base 14 drives the multiple rollers 16 to flip and open at 90 degrees to the ground, thereby dropping the defective glass. When there is no fragmentation signal, the PLC controller 3 stops outputting the drop signal and issues a motor start signal. The solenoid valve 4 closes, and the multiple rollers 16 of the drop table 1 are parallel to the ground. The motor 10 starts and operates in real time, and the glass is transported through the production line normally.

Claims

1. An automatic control system for photovoltaic glass debris falling during transportation, characterized by: The invention comprises a glass defect online detection system (2) for identifying glass defects on a transmission roller (6), wherein the transmission roller (6) is connected to the entrance of a sheet drop platform (1) along the glass flow direction, a photoelectric sensor (7) is provided at the entrance of the sheet drop platform (1), a digital signal output end of the photoelectric sensor (7) is connected to the digital signal input end of a PLC controller (3), the digital signal output end of the glass defect online detection system (2) is connected to the digital signal input end of the PLC controller (3), the PLC controller (3) is signal-connected to a solenoid valve (4), and the solenoid valve (4) is arranged in a pipeline connecting a cylinder (5) on the sheet drop platform (1) and a gas storage tank (8).

2. The automatic control system for photovoltaic glass debris falling during transportation according to claim 1, characterized in that: The sheet dropping platform (1) is provided with a crank connecting rod (13) connected to the piston rod (12) of the cylinder (5), the crank connecting rod (13) is connected to the base (14), a plurality of rollers (16) are provided on the base (14) through a bearing seat (15), a pulley (17) and a plurality of rollers (18) are provided on the rollers (16), the pulleys (17) are connected to each other through an O-belt (11), the rollers (16) are connected to the power output end of the reducer (19) through a stepped shaft (20), the power input end of the reducer (19) is connected to the power output end of the motor (10), and the signal input end of the motor (10) is connected to the signal output end of the PLC controller (3) through a frequency converter (9).

3. The automatic control system for photovoltaic glass debris falling during transportation according to claim 1, characterized in that: The glass defect online detection system (2) comprises an image acquisition unit (21) and an image processing unit (22) connected in sequence; the image acquisition unit (21) comprises a light source (210) and a CCD12 camera (211), and the light source (210) and the CCD12 camera (211) are located on both sides of the glass panel to be detected; the image processing unit (22) comprises an image acquisition card (220), a DSP image processing module (221) and a signal conversion module (222) connected in sequence; the signal output end of the CCD12 camera (211) is connected to the signal input end of the image acquisition card (220), the signal output end of the image acquisition card (220) is connected to the signal input end of the DSP image processing module (221), the signal output end of the DSP image processing module (221) is connected to the signal input end of the signal conversion module (222), and the signal output end of the signal conversion module (222) is connected to the signal input end of the PLC controller (3).

4. The automatic control system for falling debris during photovoltaic glass transportation according to claim 1 or 2, characterized in that: A glass hopper (23) is provided below the sheet dropping platform (1).

5. The automatic control system for falling debris during photovoltaic glass transmission according to claim 2, characterized in that: The rollers (16) are arranged in parallel.

6. The automatic control system for falling debris during photovoltaic glass transportation according to claim 2 or 5, characterized in that: The roller (16) is provided with a pulley (17) and two rollers (18).

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