A detection and sorting palletizing device

Abstract

The utility model discloses a kind of detection classification stacking device, it includes conveying line, camera module, image processing unit, classification stacking mechanism and handling mechanism, the camera module, the handling mechanism are electrically connected with the image processing unit;The classification stacking mechanism includes mounting bracket and the several layers of storage rack that are spaced up and down on the mounting bracket, conveying storage unit is set up on each layer the storage rack, the same layer conveying storage unit is set up into the defective material of the same type defect storage, the handling mechanism includes several adsorption units.The utility model not only improves the accuracy of defect detection and sorting efficiency, also reduces detection cost through intelligent, flexible design.

Description

Technical Field

[0001] This utility model belongs to the field of palletizing equipment technology, and in particular relates to a detection, classification and palletizing device. Background Technology

[0002] After the frames of photovoltaic modules are cut, drilled, and chamfered, they need to be visually inspected. In order to improve inspection efficiency and accuracy, it is urgent to design automated equipment to perform visual inspection on the frames.

[0003] In the prior art, the Chinese invention patent authorization announcement CN118527375B discloses a fully automatic frame inspection and stacking equipment, which can realize the inspection of both ends of the photovoltaic module frame and the entire side. After the inspection is completed, the good products are stacked up, and the defective products after inspection are transported by the waste removal and handling mechanism to the waste discharge conveyor line for transport. The following problems exist in the handling and transportation of defective products: (1) The defective products after inspection are all placed together on the waste discharge conveyor line. The defective products are not classified, and the actual defect type of the frame is not clear, which is not conducive to the improvement of the frame quality. Moreover, if the frames with different types of defects are placed together, if some frames have dirt defects, it will also contaminate other frames. If there are only some dirt defects on the frame, they can be wiped and reused after wiping and other treatments. However, the defective products are not classified, and it is necessary to find the dirty defective frames from a whole pile of defective products, which wastes time and has low work efficiency. (2) The waste removal and handling mechanism is only equipped with one gripper, which can only grip one frame at a time. If there are multiple defective products in the same group of inspection frames, it is necessary to grip them multiple times, and the handling efficiency is very low.

[0004] Therefore, it is necessary to provide a detection, sorting, and palletizing device to solve the above-mentioned technical problems. Utility Model Content

[0005] The main purpose of this invention is to provide a detection, sorting and palletizing device that not only improves the accuracy of defect detection and sorting efficiency, but also reduces detection costs through intelligent and flexible design.

[0006] This utility model achieves the above objectives through the following technical solution: a detection, classification, and palletizing device, comprising: Conveyor line; The camera module takes pictures of the materials; A sorting and palletizing mechanism includes a mounting frame and several layers of storage racks spaced vertically on the mounting frame, with each layer of storage racks equipped with a conveying and storage unit; The conveying mechanism includes several adsorption units; The image processing unit is electrically connected to both the camera module and the conveying mechanism.

[0007] Furthermore, the image processing unit incorporates a visual analysis algorithm.

[0008] Furthermore, the conveying mechanism includes a first driving member, a first support plate that moves back and forth along the conveying direction of the conveying line driven by the first driving member, a second driving member disposed on the first support plate, a push rod that moves up and down driven by the second driving member, and a mounting plate disposed at the bottom of the push rod, with a plurality of adsorption units disposed at the bottom of the mounting plate.

[0009] Furthermore, the adsorption unit includes a connecting module and a plurality of suction cups disposed at the bottom of the connecting module.

[0010] Furthermore, the connection module includes a first connection plate and a plurality of connection blocks disposed below the first connection plate by means of an elastic component, the suction cup is disposed at the bottom of the connection block, and the connection block is provided with air holes inside.

[0011] Furthermore, a blocking assembly is provided on the conveyor line below the input end of the conveying and storage unit. The blocking assembly includes a first blocking plate that blocks the forward conveying of defective products, a first blocking drive that drives the first blocking plate to move up and down or rotate, and a first sensor that senses defective products.

[0012] Furthermore, the conveying and storage unit includes a motor mounted on the storage rack, a rotating shaft driven by the motor to rotate horizontally, and conveying support assemblies mounted at both ends of the rotating shaft and perpendicular to the length direction of the rotating shaft.

[0013] Furthermore, the conveying support assembly is equipped with a second sensor for sensing materials, and both ends of the conveying support assembly are equipped with second blocking plates to prevent materials from falling.

[0014] Furthermore, the input end of the conveyor support assembly of each layer extends out of the outside of the storage rack, so that the conveyor support assembly of each layer and the storage rack form a clearance space around each other.

[0015] Furthermore, the conveying support assembly is a belt conveyor assembly.

[0016] Compared with the prior art, the beneficial effects of the detection, classification and palletizing device of this utility model are as follows: (1) High degree of automation and high efficiency: The device integrates automatic conveying, visual inspection, defect classification, defective product sorting and palletizing and rework return, realizing full-process automated operation, greatly reducing manual intervention, improving production efficiency and inspection accuracy, and is especially suitable for large-volume, high-speed industrial production lines. (2) Intelligent image processing and accurate classification: The image processing unit is based on the embedded visual analysis algorithm, which can quickly extract image features, compare standard features, judge defects and accurately classify them (such as dirt, scratches, cracks, etc.), providing reliable data support for subsequent sorting and improving the accuracy of quality management; (3) Multi-layer classification and palletizing and space optimization: The classification and palletizing mechanism adopts a multi-layer storage rack design. Each layer has an independent conveying and storage unit that can store different types of defective products, realizing refined management; the clearance space facilitates the flexible operation of the adsorption unit, supports high-level palletizing, and saves site space; (4) Seamless return of reworked products: The conveying and storage unit (such as belt conveyor assembly) is not only used to temporarily store defective products, but also to transport qualified products after rework back to the handling mechanism, which then puts them back into the conveyor line, forming a closed-loop management and reducing material waste and manual handling costs. (5) Stable and reliable handling mechanism: The handling mechanism adopts a multi-drive combination (first drive component, second drive component) and a guide structure (first guide rod, linear bearing) to ensure that the push rod rises and falls smoothly; the adsorption unit effectively adapts to the difference in frame length and height error through group layout (multiple suction cups in X and Y directions) and elastic floating design (elastic component), ensuring that the handling process is stable and does not damage the material; (6) Real-time response and collaborative control: Through the cooperation of the first sensor and the first baffle, the system can identify defective products in real time and trigger the sorting action of the handling mechanism to ensure that the production line runs continuously without interruption and improve the overall smoothness of operation; Therefore, this device not only improves the accuracy of defect detection and sorting efficiency, but also reduces detection costs through intelligent and flexible design. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the detection, sorting, and palletizing device according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the detection, sorting and palletizing device according to an embodiment of the present invention after removing the camera module and image processing unit; Figure 3 This is a schematic diagram of the conveyor line, conveyor storage unit, and blocking assembly according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the handling mechanism according to an embodiment of the present utility model; Figure 5 This is a schematic diagram of the mounting plate and adsorption unit in an embodiment of the present invention; The numbers in the image represent: 100 - Inspection, sorting, and palletizing device; 1-Conveyor line; 2-Camera module, 21-Camera, 22-Support frame; 3-Image processing unit; 4-Classification and palletizing mechanism, 41-Mounting frame, 42-Storage rack, 43-Conveying and storage unit, 431-Motor, 432-Rotating shaft, 433-Conveying support assembly, 434-Second blocking plate, 435-Second sensor, 44-Clearing space, 45-Blocking assembly, 451-First blocking plate, 452-First blocking drive, 453-First sensor; 5-Transporting mechanism, 51-First driving component, 52-First support plate, 53-Second driving component, 54-Push rod, 56-Mounting plate, 57-Adsorption unit, 571-Connecting module, 5711-First connecting plate, 5712-Connecting block, 5713-Elastic component, 57131-Support rod, 57132-Spring, 57133-Second guide rod, 572-Suction cup, 58-First guide rod, 59-Linear bearing. Detailed Implementation

[0018] Please refer to Figures 1-5 This embodiment is a detection, classification, and palletizing device 100, which includes a conveyor line 1 for conveying frames, a camera module 2 for taking pictures of the frames, an image processing unit 3 electrically connected to the camera module 2 for processing the pictures and classifying different types of defects, a classification and palletizing mechanism 4 for classifying and palletizing defective products with different types of defects, and a transport mechanism 5 electrically connected to the image processing unit 3 for transporting defective products from the conveyor line 1 to the classification and palletizing mechanism 4 or transporting reworked and qualified frames from the classification and palletizing mechanism 4 to the conveyor line 1.

[0019] In this embodiment, the material being detected is a photovoltaic module frame. In other embodiments, it can be used to detect other materials or materials with a structure similar to that of a photovoltaic module frame. In this embodiment, the material being transported is a photovoltaic module frame, and conveyor line 1 is a belt conveyor. In other embodiments, conveyor lines with different structures can be used depending on the material being transported.

[0020] The camera module 2 includes a plurality of cameras 21 arranged in an array. These cameras are mounted above the conveyor line 1 via a support frame 22. The arrangement or layout of the cameras 21 is determined according to the actual situation. In other embodiments, the camera module 2 is located below or to the side of the conveyor line 1. Therefore, the position of the camera module 2 and the layout of each camera are determined according to the actual situation and are not limited herein.

[0021] Image processing unit 3 is an industrial control computer, an embedded processor, or a processor of other architecture. Image processing unit 3 receives images captured by camera module 2, then transmits the processed data to conveying mechanism 5, causing conveying mechanism 5 to perform corresponding grasping actions. Image processing unit 3 has an embedded visual analysis algorithm configured to perform the following actions: S1. Extract image features; S2. Compare the extracted image features with preset standard features; S3. Determine if a defect exists; S4. Classify the types of defects.

[0022] The specific operation methods of S1 to S4 mentioned above are existing technologies, and the methods in the existing technologies can be used, so they will not be described in detail here.

[0023] The conveying mechanism 5 includes a first driving member 51, a first support plate 52 driven by the first driving member 51 to move back and forth along the conveying direction of the conveyor line 1, a second driving member 53 disposed on the first support plate 52, a push rod 54 driven by the second driving member 53 to move up and down, a mounting plate 56 disposed at the bottom of the push rod 54, and a plurality of adsorption units 57 disposed at the bottom of the mounting plate 56.

[0024] Because the border is relatively long, two adsorption units 57 are arranged in the Y direction to ensure adsorption stability. The two adsorption units 57 are arranged as a group and adsorb at different positions along the length of the border. In other embodiments, the number of adsorption units 57 in the Y direction can be set according to the actual length of the material. Several groups of adsorption units 57 are arranged along the X direction to allow for the simultaneous adsorption of several borders. If there are multiple defective products in the same group of detection borders, multiple defective products can be adsorbed onto the sorting and palletizing mechanism 4 at the same time, improving the handling efficiency.

[0025] To ensure that the sorting and palletizing mechanism 4 can stack a high number of layers, the push rod 54 is relatively long. The specific length of the push rod 54 is set according to the actual situation and is not limited here. To ensure the stability of the push rod 54's up-and-down movement, a first guide rod 58 is fixed on the mounting plate 56. The top end of the first guide rod 58 is movably mounted on the first support plate 52. Specifically, the first guide rod 58 is movably mounted on the first support plate 52 via a linear bearing 59.

[0026] The adsorption unit 57 includes a connecting module 571 disposed at the bottom of the mounting plate 56 and a plurality of suction cups 572 disposed at the bottom of the connecting module 571. In this embodiment, the connecting module 571 includes a first connecting plate 5711 and a plurality of connecting blocks 5712 disposed below the first connecting plate 5711. The suction cups 572 are disposed at the bottom of the connecting blocks 5712, and the connecting blocks 5712 have air holes inside, which communicate with the suction cups 572 to facilitate the passage of gas to achieve the adsorption action. All connecting blocks 5712 are connected to the bottom of the first connecting plate 5711 via elastic components 5713. The elastic components 5713 include a support rod 57131 and a second guide rod 57133, the lower end of which is fixed to the connecting block 5712 and the upper end is movably disposed on the first connecting plate 5711, and a spring 57132 sleeved on the outer periphery of the support rod 57131. The upper end of the spring 57132 abuts against the bottom surface of the first connecting plate 5711 and the lower end abuts against the surface of the connecting block 5712. The first connecting plate 5711 is provided with a plurality of mounting holes, and a gap is formed in the mounting holes for the support rod 57131 and the second guide rod 57133 to move up and down, so as to realize the up and down elastic floating of the connecting block 5712, thereby realizing the elastic adsorption of the frame, which can adapt to the height error of the frame, so as to ensure the stability of the handling process and not damage the material.

[0027] The sorting and palletizing mechanism 4 includes a mounting frame 41 and several layers of storage racks 42 spaced vertically on the mounting frame 41. Each layer of storage rack 42 is equipped with a conveying storage unit 43. The several layers of conveying storage units 43 are located directly above the conveyor line 1, so that the adsorption unit 57 can easily and quickly place defective frames onto the conveying storage units 43. The same layer of conveying storage units 43 is configured to store defective frames with the same type of defects. Therefore, the several layers of conveying storage units 43 can hold defective frames with various types of defects, including but not limited to: dirt, scratches, cracks, breaks, foreign objects, etc.

[0028] A blocking assembly 45 is provided on the conveyor line 1 below the input end of the conveyor storage unit 43. The blocking assembly 45 includes a first blocking plate 451 that blocks the forward conveying of defective products, a first blocking drive 452 that drives the first blocking plate 451 to move up and down or rotate, and a first sensor 453 that senses the defective frame. The detected frame is continuously output through the conveyor line 1. If the image processing unit 3 gives a good product signal, the blocking assembly 45 does not work. If it gives a defective product signal, the blocking assembly 45 starts to work. The first blocking drive 452 drives the first blocking plate 451 to extend and block the defective frame. The first sensor 453 detects the defective frame. The conveying mechanism 5 receives the signal and starts to work. According to the defect type, the conveying mechanism 5 places the defective frame on the corresponding layer of the conveyor storage unit 43.

[0029] The conveying and storage unit 43 includes a motor 431 mounted on a storage rack 42, a rotating shaft 432 driven by the motor 431 to rotate horizontally, and conveying support assemblies 433 mounted at both ends of the rotating shaft 432 and perpendicular to its length. The two conveying support assemblies 433 support the two ends of the defective frame. A second sensor 435 for sensing the frame is mounted on each conveying support assembly 433. A second blocking plate 434 is mounted at both ends of each conveying support assembly 433 to prevent the frame from falling. In other embodiments, a second blocking drive member is also provided to drive the second blocking plate 434 to move up and down or rotate. In this embodiment, the conveying support assembly 433 is a belt conveyor assembly, which not only supports both ends of the defective frame but also conveys the defective frames forward sequentially until the conveying support assembly 433 is full of defective frames. Furthermore, the conveying and storage unit 43 can be connected to other conveyor lines, facilitating the transport of defective frames to a rework station for inspection. Furthermore, some defects that can be repaired, such as dirt that can be wiped clean, can be cleaned before being placed on the conveyor support assembly 433. The conveyor support assembly 433 then transports the repaired frames in the opposite direction to the end near the handling mechanism 5. The handling mechanism 5 places the repaired and qualified frames onto the conveyor line 1, and the qualified frames continue to flow to the next workstation for further processing. In other embodiments, the structure of the conveyor support assembly 433 can be configured according to actual conditions. The structure of the conveyor support assembly 433 is not limited here; for example, it can be configured as a roller conveyor assembly. The input end of each layer's conveyor support assembly 433 extends beyond the outer side of the storage rack 42, so that each layer's conveyor support assembly 433 and the storage rack 42 form a clearance space 44 for the adsorption unit 57 to move around, facilitating the adsorption unit 57 to place the frames onto the conveyor support assembly 433.

[0030] In other embodiments, several layers of transport and storage units 43 are located on the side of the transport line 1. Correspondingly, a Y-direction transfer module can be added to the transport mechanism 5 to facilitate the transport action.

[0031] When using the inspection, classification, and palletizing device 100 provided in this solution, the conveyor line 1 continuously inputs the frame, the camera module 2 takes pictures of the frame, the image processing unit 3 receives the image taken by the camera module 2, and performs actions such as extracting image features, comparing the extracted image features with preset standard features, determining whether there are defects, and classifying the type of defects. After the inspection is completed, the frame continues to be conveyed forward. If the image processing unit 3 gives a good product signal, the blocking component 45 and the conveying mechanism 5 do not perform any actions, and the good frame flows into the next workstation via the conveyor line 1 for operation. If a defective product signal is given, the blocking component 45 starts to work, the first blocking drive component 452 drives the first blocking plate 451 to extend and block the defective frame, the first sensor 453 detects the defective frame, the conveying mechanism 5 receives the signal, and the conveying mechanism 5 starts to work. According to the defect type, the defective frame is placed on the corresponding layer's conveying storage unit 43, and the conveying storage unit 43 conveys the defective frames forward in sequence until the conveying support component 433 is full of defective frames.

[0032] The above descriptions are merely some embodiments of this utility model. For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of this utility model, and all such modifications and improvements fall within the protection scope of this utility model.

Claims

1. A detection, classification, and palletizing device, characterized in that, It includes: Conveyor line; The camera module is used to photograph materials; A sorting and palletizing mechanism includes a mounting frame and several layers of storage racks spaced vertically on the mounting frame, with each layer of storage racks equipped with a conveying and storage unit; The conveying mechanism includes several adsorption units; The image processing unit is electrically connected to both the camera module and the conveying mechanism.

2. The detection, classification, and palletizing device as described in claim 1, characterized in that: The image processing unit is an embedded processor.

3. The detection, classification, and palletizing device as described in claim 1, characterized in that: The conveying mechanism includes a first driving component, a first support plate that moves back and forth along the conveying direction of the conveyor line driven by the first driving component, a second driving component disposed on the first support plate, a push rod that moves up and down driven by the second driving component, and a mounting plate disposed at the bottom of the push rod, with a plurality of adsorption units disposed at the bottom of the mounting plate.

4. The detection, classification, and palletizing device as described in claim 3, characterized in that: The adsorption unit includes a connecting module and several suction cups disposed at the bottom of the connecting module.

5. The detection, classification, and palletizing device as described in claim 4, characterized in that: The connection module includes a first connection plate and a plurality of connection blocks disposed below the first connection plate by means of an elastic component. The suction cup is disposed at the bottom of the connection block, and the connection block is provided with air holes inside.

6. The detection, classification, and palletizing device as described in claim 1, characterized in that: A blocking assembly is provided on the conveyor line below the input end of the conveying and storage unit. The blocking assembly includes a first blocking plate that blocks defective products from being conveyed forward, a first blocking drive that drives the first blocking plate to move up and down or rotate, and a first sensor that senses defective products.

7. The detection, classification, and palletizing device as described in claim 1, characterized in that: The conveying and storage unit includes a motor mounted on the storage rack, a rotating shaft driven by the motor to rotate horizontally, and conveying support assemblies mounted at both ends of the rotating shaft and perpendicular to the length direction of the rotating shaft.

8. The detection, classification, and palletizing device as described in claim 7, characterized in that: The conveying support assembly is equipped with a second sensor for sensing materials, and both ends of the conveying support assembly are equipped with second blocking plates to prevent materials from falling.

9. The detection, classification, and palletizing device as described in claim 7, characterized in that: The input end of the conveyor support assembly of each layer extends out of the outside of the storage rack, so that the conveyor support assembly of each layer and the storage rack form a clearance space around each other.

10. The detection, classification, and palletizing device as described in claim 7, characterized in that: The conveyor support assembly is a belt conveyor assembly.

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