Double-balance-wheel sorting machine for ring-pull can production line

Abstract

The double-balance-wheel sorting machine comprises a rack assembly, a double-balance-wheel assembly, a driving system, a multi-mode detection unit and a control module, the first balance wheel assembly and the second balance wheel assembly are driven by independent servo motors respectively, the sorting distance is shortened to 120 mm through time-sharing control logic alternate actions, and the multi-mode detection unit and the control module are connected with the first balance wheel assembly and the second balance wheel assembly. The adaptive production line speed is 1-3 m / s, and the sorting efficiency reaches 3200 cans / min and is improved by 77.8% compared with that of traditional equipment; the multi-modal detection unit integrates a laser distance measuring sensor (detecting tank height deviation + / -0.3 mm), a near-infrared spectrometer (identifying liquid residue precision is greater than or equal to 95%) and a high-speed industrial camera (capturing surface defects at 1000 fps), multi-dimensional accurate judgment is realized in combination with a defect identification algorithm, and the error removal rate is less than 0.1%.

Description

Technical Field

[0001] This invention relates to the field of automated sorting equipment technology, specifically a double-swing wheel sorting machine for aluminum can production lines, suitable for the precise rejection of defective aluminum cans in high-speed beverage production lines, especially for real-time detection and sorting of can deformation, liquid residue and surface defects. Background Technology

[0002] A swing wheel sorter is an automated device widely used in logistics sorting systems. Its core function is to guide goods along a designated path using an array of swing wheels with adjustable direction. The basic structure of a traditional swing wheel sorter includes a drive system, a swing wheel assembly, a conveyor belt frame, and a control system. Its working principle is as follows: when goods enter the sorting area, sensors detect the position of the goods and sorting information, control the rotation direction of the swing wheel assembly, and use the friction force on the surface of the swing wheels to change the movement trajectory of the goods, thereby achieving sorting.

[0003] In existing technologies, traditional can sorting equipment mostly adopts a single pendulum wheel structure, relying on a single drive system to synchronously control the conveying and sorting actions. This results in a sorting distance of ≥300mm to avoid collision risks, making it difficult to adapt to the needs of high-speed production lines (≥3000 cans / minute). At the same time, the detection unit is mostly based on a single photoelectric sensor (such as patent CN202110123456.8), which cannot accurately identify liquid residue or minor deformations inside the can, resulting in a false rejection rate as high as 5%-8%.

[0004] Existing swing wheel sorting machines suffer from inherent limitations in sorting efficiency and density due to their single-drive system and continuous operation mode. There is an urgent need for a novel mechanical structure design that, through time-sharing drive and dynamic collaborative control, can substantially optimize sorting spacing and improve sorting efficiency. Utility Model Content

[0005] In view of this, the purpose of the present invention is to provide a double-swing wheel sorting machine for a can production line, which achieves a sorting distance of ≤120mm and a rejection rate of <0.1% by using double-swing wheel time-sharing drive and multi-modal detection technology.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A dual-swing wheel sorting machine for sorting aluminum cans includes a frame assembly, a dual-swing wheel assembly, a drive system, a multimodal detection unit, and a control module. The frame assembly supports the main body of the sorting machine and is adapted to the production line's transmission track. Each set of swing wheels in the dual-swing wheel assembly is driven by an independent servo motor, achieving alternating oscillation through time-sharing control logic. The drive system includes a first servo motor, a second servo motor, and a third drive motor. The first servo motor drives each swing wheel to rotate through a transmission mechanism, realizing product conveying. The second and third servo motors are respectively connected to the first and second swing wheel assemblies, driving the corresponding swing wheel sets to oscillate through the swing assembly, thus rejecting defective aluminum cans. The control module is integrated into the electrical box and configured with time-sharing control logic to coordinate the timing of the actions of the two sets of swing wheel assemblies. The multimodal detection unit includes a photoelectric sensor array and a visual recognition module, respectively arranged at the feeding end and the sorting area.

[0008] Furthermore, the transmission mechanism includes: a chain drive system consisting of a drive sprocket and a chain, a belt drive system consisting of a belt roller and an O-belt, and a rotary support structure consisting of a bearing housing and a bearing. The chain drive system is used for the transmission connection between the first servo motor and each belt roller; and for the synchronous drive of each balance wheel.

[0009] Furthermore, the balance wheel assembly includes: an eccentric adjustment assembly consisting of an eccentric clamp and an eccentric clamp shaft, used to adjust the swing angle of the balance wheel; a crankshaft connecting rod mechanism, used to convert the rotational motion of the second servo motor / third servo motor into the reciprocating swing of the eccentric clamp; the eccentric clamp shaft is hinged to the balance wheel mounting base through a bearing.

[0010] Furthermore, the control module communicates with the host computer via the MODBUS-TCP protocol and integrates: a position detection unit, which tracks the product position in real time based on photoelectric sensor signals; a timing control unit, used to control the alternating action interval of the two sets of balance wheel assemblies; and an overload protection unit, used to monitor the current threshold of the drive motor and trigger shutdown protection.

[0011] Furthermore, the diameter of the balance wheel is 50-80mm, and the distance between adjacent balance wheels is 20-40mm.

[0012] Furthermore, the drive system includes a precision reducer with a reduction ratio of 1:20-1:30, adapted to production line speeds of 1-3 m / s.

[0013] Furthermore, the multimodal detection unit includes:

[0014] A laser rangefinder sensor is used to detect the height deviation of an aluminum can.

[0015] Near-infrared spectrometer is used to identify the amount of liquid residue in the tank;

[0016] High-speed industrial cameras are used to capture dents or scratches on the surface of tanks.

[0017] Furthermore, the frame assembly includes a bottom cover plate and an upper flat cover plate, and the double swing wheel assembly is arranged between the bottom cover plate and the upper flat cover plate. The bottom cover plate and the upper flat cover plate are laser-cut from 304 stainless steel plates and have an array of heat dissipation holes on their surfaces.

[0018] Furthermore, the surface of the double balance wheel assembly is covered with a food-grade silicone layer and is designed with micro-bumps.

[0019] Furthermore, the control module integrates a defect identification algorithm to identify defective products based on signals from the visual recognition module.

[0020] This invention, through a dual-ballast wheel time-sharing drive combined with a multi-modal detection unit, has the following significant advantages over existing technologies:

[0021] 1. Efficiency breakthrough: The sorting distance is reduced by 60%, the efficiency is increased by 77.8%, and the production line speed is supported to be ≥3m / s;

[0022] 2. Precise rejection: The overall accuracy of multimodal detection is ≥99.9%, and the false rejection rate is <0.1%;

[0023] 3. Hygiene Compliance: Food-grade materials and a closed design meet GB 4806.1-2016 standards;

[0024] 4. High reliability: Independent drive redundancy design, MTBF≥3000 hours. Attached Figure Description

[0025] Figure 1 A front view of a double-pinwheel sorting machine is shown according to some embodiments of the present invention;

[0026] Figure 2 A top view of a double-pinwheel sorting machine is shown according to some embodiments of the present invention;

[0027] Figure 3 According to some embodiments of the present invention, a schematic diagram of the internal structure of a double-pinwheel sorting machine is shown;

[0028] Figure 4 According to some embodiments of the present invention, a left view of a double-pinwheel sorting machine is shown. Detailed Implementation

[0029] The technical features and advantages of this application will be described in more detail below with reference to the accompanying drawings, so that the advantages and features of this application can be more easily understood by those skilled in the art, thereby making a clearer and more explicit definition of the scope of protection of this invention.

[0030] It should be noted that in the description of this application, the terms "upper", "lower", "left", "right", "inner", "outer", etc., indicating directions or positional relationships are based on the directions or positional relationships shown in the drawings. This is only for the convenience of description and is not intended to indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of the present invention.

[0031] The terms “first” and “second” are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly indicating the importance of the technical features shown.

[0032] Furthermore, it should be noted that, in the description of this application, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0033] Please see Figures 1-4 This invention provides a double-swing wheel sorting machine for a beverage can production line, the overall structure of which includes:

[0034] Frame assembly 1: Adaptable to the production line's transmission track, which can be designed as an adjustable width guide rail (80-150mm) to match different tank diameters (φ50-φ80mm).

[0035] Double balance wheel assembly: Each balance wheel assembly contains 12 balance wheels 211, which rotate synchronously through a chain drive structure;

[0036] Drive system: includes a first servo motor 31, a second servo motor 32 and a third servo motor 33. The first servo motor 31 drives each swing wheel to rotate synchronously to realize the conveying of cans; the second servo motor 32 and the third servo motor 33 independently control the swing of two sets of swing wheel assemblies to realize sorting.

[0037] Detection Unit: Defects are detected by combining laser ranging, near-infrared spectroscopy, and high-speed camera.

[0038] Control module: The time-sharing control logic enables the alternating motion of the two sets of balance wheel assemblies.

[0039] The core innovations of this invention are as follows:

[0040] 1. Time-based rejection mechanism: When the first set of balance wheel assemblies is being sorted, the second set of balance wheel assemblies is on standby, and the minimum sorting distance can be shortened to 120mm;

[0041] 2. Multimodal detection: Near-infrared spectroscopy (detecting liquid residue) + laser array (locating deformation) + visual recognition (surface defects) collaborative judgment;

[0042] 3. Dynamic adjustment mechanism: The eccentric clamping shaft (eccentricity 1-3mm) is linked with the crankshaft connecting rod mechanism to support the adjustment of the balance wheel angle.

[0043] The following is a detailed description of each functional component, with reference to the accompanying drawings:

[0044] Frame assembly 1 includes a leg 11, side plates 12, a bottom cover plate 13, and a top cover plate 14. The leg 11 can be a welded frame made of square tubing with a food-grade epoxy resin coating. The side plates 12 can be formed by bending 304 stainless steel frosted sheet and have positioning holes. The bottom cover plate 13 and the top cover plate 14 can be formed by laser cutting 304 stainless steel sheet, forming a space for the arrangement of the swing wheel assembly between them. The surface is provided with an array of heat dissipation holes (3mm diameter, 10mm spacing). Frame assembly 1 provides rigid support and is compatible with the production line track. It can be connected to a waste collection trough (tilted at 15°) and uses a vibrating motor to guide and remove defective cans. In an optimized embodiment, an ultraviolet sterilization module can also be integrated on top of frame assembly 1 to sterilize and disinfect the passing cans.

[0045] The dual-balance wheel assembly includes a first balance wheel assembly 21 and a second balance wheel assembly 22. Each balance wheel assembly contains a balance wheel array consisting of 12 balance wheels 211. Each balance wheel 211 has a diameter of 50-80mm, a polyurethane composite matrix, and a food-grade silicone layer (2mm thick, Shore A hardness 60A-70A) on its surface. It is also designed with anti-slip micro-protrusions (0.5mm high) to prevent the can from slipping. Each balance wheel 211 is equipped with a rotating shaft 212, which is precision machined from 45# steel and connected to the balance wheel 211 via a flat key 213. The balance wheel 211 is rotatably mounted on the balance wheel mounting base 214 via the rotating shaft 212. The first servo motor 31 drives each balance wheel 211 to rotate at a uniform speed (linear speed 1-3m / s) through the first reducer 34 and the transmission mechanism, thereby realizing the conveying of the can. The transmission mechanism includes a chain drive mechanism and a belt drive mechanism. The chain drive structure includes a drive sprocket 351 and a driven sprocket 352 mounted on each rotating shaft 37. The drive sprocket 351 and the driven sprocket 352 are driven by chain meshing. The first servo motor 31 drives the drive sprocket 351 to rotate, and then drives each rotating shaft 37 to rotate synchronously through chain drive. A belt roller 361 is installed on the rotating shaft 37 at the position corresponding to the balance wheel. The belt roller 361 and the balance wheel are connected by an O-belt 362. The first servo motor 31 drives the drive sprocket 351 to rotate through the first reducer 34, and then drives each balance wheel 211 to rotate synchronously through chain drive and O-belt 362 in sequence.

[0046] The second servo motor 32 and the third servo motor 33 drive the balance wheel array through the crankshaft connecting rod mechanism 38 to achieve oscillating sorting. The oscillation principle of the balance wheel array is explained below using the second servo motor 32 as an example. The second servo motor 32 is connected to the crankshaft 381 of the crankshaft connecting rod mechanism 38 via the second reducer 39. The eccentric rotation of the crankshaft 381 drives the oscillation of the steering connecting rod 382. The balance wheels 211 in the same row are connected to the steering connecting rod 382 via a connecting rod 383. The oscillation of the steering connecting rod 382 drives a set of balance wheels to oscillate. Specifically, each balance wheel 211 is equipped with an eccentric clamp 215. One end of the eccentric clamp 215 is hinged to the connecting rod 383, and the other end is hinged to the balance wheel mounting seat 214 via the eccentric clamp shaft 216 and a bearing. The oscillation of the steering connecting rod 382 drives the balance wheel 211 to oscillate sequentially through the connecting rod 383, the eccentric clamp 215, the eccentric clamp shaft 216, and the balance wheel mounting seat 214.

[0047] High-torque conveying power is provided by chain drive (drive sprocket + chain + driven sprocket); belt drive (PU round belt + belt roller) helps stabilize the tank.

[0048] The drive system includes:

[0049] The first servo motor 31 is 400W and 3000rpm. It drives the drive sprocket 351 to rotate through the first reducer 34 (reduction ratio 1:20).

[0050] The second servo motor 32 and the third servo motor 33 are both 200W and are connected to the crankshaft connecting rod mechanism 38 and the eccentric clamp 215 via the second reducer 39.

[0051] The multimodal detection unit (not shown in the figure) includes:

[0052] Laser rangefinder sensor (KEYENCE IL-100): used to detect the height deviation of aluminum cans (±0.3mm);

[0053] Near-infrared spectrometer (Ocean Optics NIRQuest): wavelength range 1200-2500nm, used to detect liquid residue in aluminum cans (accuracy ≥95%).

[0054] High-speed industrial camera (Basler acA2000-50gm): 1000fps, used to capture defects on the surface of aluminum cans.

[0055] The multimodal detection unit uses multi-sensor data fusion and the defect identification algorithm (CNN model) of the control module to determine unqualified tanks.

[0056] The control module includes:

[0057] Main control unit (STM32H7): integrates MODBUS-TCP protocol;

[0058] Time-sharing control unit: coordinates the timing of the two sets of balance wheels;

[0059] Overload protection unit: monitors current threshold (triggers shutdown when >5A);

[0060] Position detection unit: It tracks the product position in real time based on photoelectric sensor signals, thereby triggering the sorting action of the multimodal detection unit and the corresponding balance wheel assembly (second servo motor 32 / third servo motor 33).

[0061] The control module can have a built-in hierarchical rejection strategy. Level 1 defects are rejected by the first balance wheel assembly 21, and level 2 defects are rejected by the second balance wheel assembly 22.

[0062] The working principle of this invention is as follows:

[0063] I. Testing Phase:

[0064] When an aluminum can enters the detection area, the position detection unit detects the can and triggers the multimodal detection unit to start. The laser sensor scans the height of the can, the near-infrared spectrometer analyzes the liquid residue, and the high-speed camera captures surface defects.

[0065] The control module integrates data to determine whether the aluminum can is qualified and its defect level.

[0066] II. Sorting Stage:

[0067] Level 1 defect (minor deformation): The first balance wheel assembly 21 is activated, pushing the tank into the first waste trough for sorting;

[0068] Level 2 defect (serious leakage): The second balance wheel assembly 22 is activated, pushing the tank sorting material into the second waste trough;

[0069] The time-sharing control logic ensures that the interval between the two sets of swing wheels is ≤200ms, and the sorting distance is reduced to 120mm.

[0070] III. Reset Phase:

[0071] After sorting is completed, the double pendulum wheel assembly is reset to its initial angle and awaits the next detection signal.

[0072] Example 1: High-speed beverage production line

[0073] Production line parameters: speed 2.5m / s, tank diameter φ66mm;

[0074] Sorting results:

[0075] Sorting distance: 120mm (300mm for traditional equipment);

[0076] Sorting efficiency: 3200 cans / minute, a 77.8% improvement compared to single-wheel equipment (1800 cans / minute);

[0077] False rejection rate: 0.05% (5% for traditional equipment).

[0078] Example 2: Aseptic Filling Workshop

[0079] Special design:

[0080] The surface of rack assembly 1 is coated with an antibacterial coating;

[0081] Balance wheel 211 can be detached and sterilized (high-pressure steam 121℃, 30 minutes).

[0082] Sorting results:

[0083] Sorting accuracy: Surface scratch detection sensitivity 0.1mm²;

[0084] Hygiene indicators: Microbial residue <1 CFU / cm² (compliant with GB 4789.2-2016).

[0085] Example 3: Sorting of multi-size cans

[0086] Adaptation solution:

[0087] Adjust the width of the guide rails of frame assembly 1 (80-150mm).

[0088] Replace the balance wheel spacing (20-40mm).

[0089] Sorting results:

[0090] Switching time: <10 minutes;

[0091] Versatility: Supports sorting of cans with diameters from φ50 to φ80mm.

[0092] The dual-swing wheel sorting machine of this invention achieves high-speed sorting (≥3200 cans / minute) and accurate rejection (false rejection rate <0.1%) of aluminum cans through dual-swing wheel time-sharing drive and multimodal detection technology. The sorting distance is reduced to 120mm, which significantly improves the efficiency of the production line and is suitable for the beverage, food and pharmaceutical industries.

[0093] In the description of this specification, references to terms such as "some embodiments," "some examples," "exemplarily," "example," "preferred," or "further" indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0094] The above description is merely an embodiment of this application and does not limit the patent scope of this application. Any equivalent structural or procedural transformations made based on the content of this specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. A double-swing wheel sorting machine for a beverage can production line, characterized in that, include: Frame assembly, used to support the main body of the sorting machine and adapt to the production line conveyor track; The dual-balance wheel assembly is driven by an independent servo motor, and the alternating oscillation is achieved through time-sharing control logic. The drive system includes a first servo motor, a second servo motor, and a third drive motor. The first servo motor drives each swing wheel to rotate through a transmission mechanism to realize the conveying of products. The second and third servo motors are respectively connected to the first and second swing wheel assemblies and drive the corresponding swing wheel groups to swing through the swing assembly to realize the rejection of unqualified aluminum cans. The control module, integrated into the electrical box, is configured with time-sharing control logic to coordinate the timing of the actions of the two sets of balance wheel assemblies; The multimodal detection unit, comprising an array of photoelectric sensors and a vision recognition module, is arranged at the feeding end and the sorting area, respectively.

2. The double-swing wheel sorting machine according to claim 1, characterized in that, The transmission mechanism includes: A chain drive system consisting of a drive sprocket and a chain is used for the transmission connection between the first servo motor and each belt roller; A belt drive system consisting of belt rollers and O-belts is used for the synchronous drive of each balance wheel; A rotating support structure consisting of a bearing housing and a bearing.

3. The double-swing wheel sorting machine according to claim 1, characterized in that, The balance wheel assembly includes: An eccentric adjustment assembly, consisting of an eccentric clamp and an eccentric clamp shaft, is used to adjust the swing angle of the balance wheel. The crankshaft connecting rod mechanism is used to convert the rotary motion of the second servo motor / third servo motor into the reciprocating oscillation of the eccentric clamp; The eccentric clamping shaft is hinged to the balance wheel mounting base via a bearing.

4. The double-swing wheel sorting machine according to claim 1, characterized in that, The control module communicates with the host computer via the MODBUS-TCP protocol and integrates: A location detection unit that tracks product position in real time based on photoelectric sensor signals; The timing control unit is used to control the alternating interval of the two sets of balance wheel assemblies; The overload protection unit is used to monitor the current threshold of the drive motor and trigger shutdown protection.

5. The double-swing wheel sorting machine according to claim 1, characterized in that, The diameter of the balance wheel is 50-80mm, and the distance between adjacent balance wheels is 20-40mm.

6. The double-swing wheel sorting machine according to claim 1, characterized in that, The drive system includes a precision reducer with a reduction ratio of 1:20-1:30, which is suitable for production line speeds of 1-3 m / s.

7. The double-swing wheel sorting machine according to claim 1, characterized in that, The multimodal detection unit includes: A laser rangefinder sensor is used to detect the height deviation of an aluminum can. Near-infrared spectrometer is used to identify the amount of liquid residue in the tank; High-speed industrial cameras are used to capture dents or scratches on the surface of tanks.

8. The double-swing wheel sorting machine according to claim 1, characterized in that, The frame assembly includes a bottom cover plate and an upper flat cover plate. The double swing wheel assembly is arranged between the bottom cover plate and the upper flat cover plate. The bottom cover plate and the upper flat cover plate are laser-cut from 304 stainless steel plates and have an array of heat dissipation holes on their surfaces.

9. The double-swing wheel sorting machine according to claim 1, characterized in that, The surface of the double balance wheel assembly is covered with a food-grade silicone layer and is designed with micro-protrusions.

10. The double-swing wheel sorting machine according to claim 1, characterized in that, The control module integrates a defect identification algorithm, which is used to identify defective products based on signals from the visual recognition module.

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