Unstacker control system based on visual analysis
By precisely controlling the magnetism of the electromagnet in the destacking machine through a visual analysis system, the automation problem of the steel destacking machine has been solved, and efficient and safe destacking operations have been achieved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- TANGSHAN ZHENGFENG NEW MATERIALS CO LTD
- Filing Date
- 2025-08-13
- Publication Date
- 2026-05-26
AI Technical Summary
Existing steel destacking machines suffer from inaccurate steel material picking due to the inability to precisely adjust the magnetism of the electromagnets, resulting in steel loss or over-pickup. They cannot achieve automated destacking, rely on manual assistance, and are inefficient and dangerous.
The destacking machine control system adopts vision analysis, which collects photos through inlet and outlet cameras, performs data analysis in combination with light source, generates the number of steel sections, and controls the magnetic adjustment of the destacking machine electromagnet to achieve precise picking.
It has enabled the depalletizer to operate automatically, improving production efficiency, reducing labor costs and safety hazards, and eliminating the safety risks of manual operation.
Smart Images
Figure CN224279004U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to a destacking machine control system based on visual analysis, belonging to the technical field of steel destacking application equipment in the metallurgical industry. Background Technology
[0002] In the hot-dip galvanizing process of structural steel, the material loading area before pickling requires destacking the stacked materials, separating the layers of structural steel one by one. Currently, most structural steel destacking machines used domestically and internationally employ electromagnet control for direct destacking. However, due to the inability to precisely adjust the magnetism of the electromagnet and the irregularity of the structural steel materials, when the electromagnet picks up each layer of material, if the magnetism is too weak, steel will be lost, and a layer will not be completely picked up. If the magnetism is too strong, it will simultaneously pick up the next layer of structural steel, making separation impossible. In such cases, destacking can only be completed manually, which is not only inefficient but also labor-intensive and dangerous, clearly failing to meet the needs of automated production lines. Utility Model Content
[0003] The purpose of this invention is to provide a depalletizer control system based on visual analysis. By adjusting the magnetism of the electromagnet through visual analysis, the problem of the electromagnet attracting too little or too much magnetism can be solved, thereby realizing the automated operation of the depalletizer and solving the problems existing in the background technology.
[0004] The technical solution of this utility model is:
[0005] A visual analysis-based destacking machine control system includes a steel conveying roller conveyor, a destacking machine, and a destacking machine electromagnet. The system also includes an inlet light source, an inlet camera, an outlet light source, an outlet camera, an inlet camera gantry, and an outlet camera bracket. The inlet camera gantry is installed at the inlet of the conveying roller conveyor, and the inlet light source and inlet camera are respectively fixed on the inlet camera gantry. The outlet camera bracket is installed at the inlet and outlet of the conveying roller conveyor, and the outlet light source and outlet camera are respectively fixed on the outlet camera bracket.
[0006] The inlet light source and inlet camera are respectively aligned with the center line of the steel material on the steel conveying roller conveyor and the rear end face of the steel material, while the outlet light source and outlet camera are respectively aligned with the center line of the steel material on the steel conveying roller conveyor and the front end face of the steel material.
[0007] Furthermore, the inlet camera and the outlet camera are installed at the same height, both above the steel conveyor rollers.
[0008] Furthermore, the entrance light source is located below the entrance camera, and the exit light source is located below the exit camera, with the entrance light source and the exit light source having the same installation height.
[0009] Furthermore, the entrance camera and the exit camera are connected to the vision acquisition and analysis host via the destacking machine PLC controller.
[0010] The vision acquisition and analysis host receives vision acquisition commands from the destacking machine's PLC controller, sends image acquisition commands to the camera, and analyzes and stores the acquired images. Through data analysis and calculation, it ultimately generates the number of steel sections and feeds this number back to the destacking machine's PLC controller. The destacking machine's PLC controller controls the destacking machine's lifting, translation, and tilting, as well as the magnetization, demagnetization, and electromagnetic adjustment of the electromagnets, and sends vision acquisition commands to the vision host.
[0011] The beneficial effects of this utility model are: the vision system can accurately judge the state of the electromagnet picking up materials, and the magnetic force adjustment can improve the success rate of the electromagnet picking up materials, thereby realizing the automatic operation of the destacking machine, reducing labor costs, eliminating safety hazards during manual operation, reducing the accident rate, and improving production efficiency. Attached Figure Description
[0012] Figure 1 This is a schematic diagram of the device structure of this utility model;
[0013] Figure 2 This is a block diagram of the control system of this utility model;
[0014] In the diagram: 1. Steel conveyor roller; 2. Destacking machine; 3. Destacking machine electromagnet; 4. Grouping chain bed; 5. Steel profile material; 6. Entrance light source; 7. Entrance camera; 8. Exit light source; 9. Exit camera; 10. Entrance camera gantry; 11. Exit camera bracket; 12. Destacking machine PLC controller; 13. Host computer; 14. Vision acquisition and analysis host. Detailed Implementation
[0015] The present invention will be further described below with reference to the accompanying drawings and examples.
[0016] See attached document Figure 1 , 2 A visual analysis-based destacking machine control system includes a steel conveying roller conveyor 1, a destacking machine 2, and a destacking machine electromagnet 3. The system also includes an inlet light source 6, an inlet camera 7, an outlet light source 8, an outlet camera 9, an inlet camera gantry 10, and an outlet camera bracket 11. The inlet camera gantry 10 is installed at the inlet of the conveying roller conveyor 1. The inlet light source 6 and the inlet camera 7 are respectively fixed on the inlet camera gantry 10. The outlet camera bracket 11 is installed at the inlet and outlet of the conveying roller conveyor 1. The outlet light source 8 and the outlet camera 9 are respectively fixed on the outlet camera bracket 11.
[0017] In this example, refer to the appendix. Figure 1 , 2The vision-based destacking machine control system includes a steel conveyor roller 1, a destacking machine 2, a destacking machine electromagnet 3, a grouping chain bed 4, steel profile material 5, an inlet light source 6, an inlet camera 7, an outlet light source 8, an outlet camera 9, an inlet camera gantry 10, an outlet camera bracket 11, a destacking machine PLC controller 12, a host computer 13, and a vision acquisition and analysis host 14. The inlet camera gantry 10 is installed at the inlet of the conveyor roller 1, spanning the roller 1. The inlet camera 7 is mounted on the inlet camera gantry 10, with its installation height 1200mm above the upper surface of the conveyor roller 1. The mounting position is aligned with the centerline of the steel profile material 5. The installation direction is aligned with the rear end face of the steel material 5. The inlet light source 6 is installed on the inlet camera gantry 10, located 100mm directly below the inlet camera 7, and the installation direction is aligned with the rear end face of the steel material 5. An outlet camera bracket 11 is installed at the end of the conveying roller 1, and an outlet camera 9 is installed on the outlet camera bracket 11. The installation height is 1200mm higher than the upper surface of the conveying roller 1, and the installation position is aligned with the center line of the steel material 5. The installation direction is aligned with the front end face of the steel material 5. The outlet light source 8 is installed on the outlet camera bracket 11, located 100mm directly below the outlet camera 9, and the installation direction is aligned with the front end face of the steel material 5.
[0018] The visual acquisition and analysis host 14 control system receives the visual acquisition command from the destacking machine PLC controller 12, sends a photo acquisition command to the camera, performs data analysis and storage based on the acquired photos, generates the final number of steel sections through data analysis and calculation, and feeds the number of sections back to the destacking machine PLC controller 12.
[0019] The PLC controller 12 of the depalletizer is used to control the lifting, translation, and flipping of the depalletizer, as well as the magnetization, demagnetization, and electromagnetic adjustment of the electromagnet. It also sends visual acquisition commands to the visual acquisition and analysis host, receives the analysis results of the acquired photos from the visual acquisition and analysis host, and controls the electromagnet of the depalletizer to perform different operation types according to the analysis results. For details of the specific types, please refer to Table 1. When the electromagnet of the depalletizer is normally attracted, the next operation is performed.
[0020] Table 1
[0021]
[0022] The depalletizer control method is operated according to the following steps:
[0023] Step A1: On the host computer 13, the operator sets the electromagnet 3 of the destacking machine to attract magnetic force based on experience values;
[0024] Step A2: The destacking machine PLC controller 12 receives the information that the steel material 5 has been placed in place and turns on the inlet light source 6 and the outlet light source 8.
[0025] Step A3: The PLC controller 12 of the destacking machine controls the destacking machine 2 to start picking up the upper layer of steel material;
[0026] Step A4: When the lifting motor of the depalletizer 2 stops after the depalletizer electromagnet 3 has picked up the material and lifted it by 100mm, a visual recognition command is sent to the visual acquisition and analysis host 14.
[0027] Step A5: The visual acquisition and analysis host 14 receives the visual recognition instruction, sends the photo-taking instruction to the entrance camera 7 and the exit camera 9 respectively, and acquires photos from the cameras.
[0028] Step A6: The visual acquisition and analysis host 14 generates the final number of steel sections absorbed at the inlet and outlet through data analysis and calculation based on the acquired photos.
[0029] Step A7: The visual acquisition and analysis host 14 feeds back the generated number of items to the depalletizer PLC controller 12;
[0030] Step A8: The destacking machine PLC controller 12 receives the judgment result from the vision acquisition and analysis host 14. When the number of material pieces photographed by the inlet camera 7 and the outlet camera 9 is normal, execute A13. When the number of material pieces photographed by the inlet camera 7 and the outlet camera 9 is missing one piece on one side, execute A9. When the number of material pieces photographed by the inlet camera 7 and the outlet camera 9 is less than 2 on one side or missing one piece on both sides, execute A10. When the number of material pieces photographed by the inlet camera 7 and the outlet camera 9 is extra one on one side, execute A11. When the number of material pieces photographed by the inlet camera 7 and the outlet camera 9 is more than 2 on one side or extra one piece on both sides, execute A12.
[0031] Step A9: The PLC controller 12 of the depalletizer controls the depalletizer 2 to put down the material of this layer. The electromagnet 3 of the depalletizer automatically increases the magnetic force by 1% and picks up the material again, and executes step A4.
[0032] Step A10: The PLC controller 12 of the depalletizer controls the depalletizer 2 to put down the material of this layer. The electromagnet 3 of the depalletizer automatically increases the magnetic force by 2% and picks up the material again, and executes step A4.
[0033] Step A11: The PLC controller 12 of the depalletizer controls the depalletizer 2 to put down the material of this layer. The electromagnet 3 of the depalletizer automatically reduces the magnetic force by 1% and picks up the material again, and executes step A4.
[0034] Step A12: The PLC controller 12 of the depalletizer controls the depalletizer 2 to put down the material of this layer. The electromagnet 3 of the depalletizer automatically reduces the magnetic force by 2% and picks up the material again, and executes step A4.
[0035] Step A13: The depalletizer PLC controller 12 controls the depalletizer 2 to place the material of the current layer onto the grouped chain bed 4, and continue to pick up the next layer of material, and then execute step A4 again.
Claims
1. A vision-based destacking machine control system, comprising a steel conveying roller conveyor (1), a destacking machine (2), and a destacking machine electromagnet (3), characterized in that: The composition also includes an inlet light source (6), an inlet camera (7), an outlet light source (8), an outlet camera (9), an inlet camera gantry (10), and an outlet camera bracket (11). The inlet camera gantry (10) is installed at the inlet of the conveyor roller (1). The inlet light source (6) and the inlet camera (7) are respectively fixed on the inlet camera gantry (10). The outlet camera bracket (11) is installed at the outlet of the conveyor roller (1). The outlet light source (8) and the outlet camera (9) are respectively fixed on the outlet camera bracket (11).
2. The depalletizer control system based on vision analysis according to claim 1, characterized in that: The inlet light source (6) and the inlet camera (7) are respectively aligned with the center line of the steel material (5) on the steel conveyor (1) and the rear end face of the steel material (5), and the outlet light source (8) and the outlet camera (9) are respectively aligned with the center line of the steel material (5) on the steel conveyor (1) and the front end face of the steel material (5).
3. The depalletizer control system based on vision analysis according to claim 2, characterized in that: The inlet camera (7) and outlet camera (9) are installed at the same height, both above the steel conveyor roller (1).
4. The depalletizer control system based on vision analysis according to claim 3, characterized in that: The entrance light source (6) is located below the entrance camera (7), and the exit light source (8) is located below the exit camera (9). The entrance light source (6) and the exit light source (8) are installed at the same height.
5. The depalletizer control system based on vision analysis according to claim 1, characterized in that: The entrance camera (7) and the exit camera (9) are connected to the vision acquisition and analysis host (14) via the destacking machine PLC controller (12).