System and method for automated unpacking of bulk products

Abstract

FIELD: bulk product unloading.SUBSTANCE: automated bulk product unloading system includes a computing unit that processes data received via a user interface, connected via a network interface and cables to a machine vision unit equipped with a 3D camera, an industrial manipulator unit with a gripping device and an unloading unit, including a cutting unit equipped with a drive, an unloading chamber and a receiving bin, as well as an aspiration unit containing a fan with a filter. The technical vision unit is designed to determine the coordinates of the position of bags on a pallet or container in the coordinate determination module using a 3D camera. The unloading unit is equipped with a shaking unit on bearings with adjustable speed and movement pattern, equipped with a drive. The receiving hopper is mounted on vibration supports kinematically connected to the drive of the shaking mechanism, designed with the ability to provide shaking at different frequencies; bent lamellas are installed on the drive part of the receiving hopper and are designed with the ability to perform wave-like movements. The computing unit includes a module for interacting with and processing data received from the machine vision unit, a module for controlling the industrial manipulator, a module for controlling the unloading chamber, which changes the movements of the lamellas and transmits commands to the drive of the shaking mechanism, a module for controlling the cutting unit, which allows positioning the cutting unit, and a module for controlling the aspiration unit.EFFECT: bag emptying rate increases (less than 0.1% of residue) for bulk food products.4 cl, 9 dwg

Description

[0001] FIELD OF TECHNOLOGY

[0002] This group of inventions relates to automated warehouse and production logistics systems, specifically robotic depalletization and primary unpacking of bulk products. The solution can be used in processing plants for automated opening and emptying of bags containing bulk products, including fine-grained products such as flour, sugar, starch, and protein.

[0003] STATE OF THE ART

[0004] Various approaches to bag unloading are known, including manual labor, semi-automated stations, and automated systems. Today, the development of such systems and methods is characterized by a shift from rigidly programmed cycles to adaptive intelligent systems. For example, this utilizes machine vision to recognize objects or various algorithms that allow the system to determine the coordinates and orientation of the bag. Robots with high payload capacities (e.g., 50 to 180 kg) and a high degree of dust and moisture protection (IP65 / IP67) have also become widely used, which is critical for handling raw materials such as flour, chemicals, or cement.

[0005] Current systems strive to ensure "clean" unloading with a high emptying rate. The problem of residual raw materials remains one of the main challenges in industrial bulk logistics. Despite technological advances, achieving 100% emptying is difficult due to the physical and chemical properties of the products and certain design limitations. For the purposes of this description, the bag / container emptying rate refers to weighing the bag before loading, then weighing the remaining product inside the bag on a scale, minus the bag material, and determining the percentage.

[0006] For example, fine powders (flour, pigments, metal oxides) adhere to the inner walls due to static electricity or humidity. And if the product has been stored for a long time, so-called caked raw materials form—lumps that become stuck in the folds of the flexible container. Flow dynamics can also play a role. During pouring, the material can form a "dome" over the outlet, slowing or completely blocking emptying, even though significant volume remains in the bag.

[0007] The presence of leftovers in a single unit of production leads to significant financial losses (underutilization of purchased raw materials) and also leads to related problems. For example, containers with chemical or dye residues require special recycling, while clean containers are disposed of as regular waste or recyclable materials.

[0008] The prior art discloses solution CN216070854U (published March 18, 2022, IPC B65 B69 / 00), which discloses an unpacking manipulator based on a machine vision system. It includes a mounting base, a mechanical manipulator mounted on one side of the upper portion of the mounting base, a material container rigidly attached to the other side of the upper portion of the mounting base, a hopper formed in the material container, one end of the bottom of the material hopper connected to a discharge opening, and the other end of the bottom of the material hopper also connected to a discharge opening.One end of the upper part of the material hopper is connected via a rotary transmission to a threaded rod. The other end of the upper part of the material hopper is rigidly connected to a limiting rod. A motor is mounted on one side of the surface of the material hopper. The outlet end of the threaded rod passes through the material hopper and is connected via a rotary transmission to the outlet end of the motor. The surface of the threaded rod is connected to two threaded bushings. According to the utility model, the cutting notch of the packaging bag is increased, the unloading speed of the device is improved, and the likelihood of large amounts of material remaining in the bag is reduced.

[0009] However, despite the enlarged cutting notch, the device does not ensure 100% emptying due to passive unloading, which can leave raw materials trapped in the folds of the bag or other packaging. Furthermore, the widened cutting notch and open design lead to uncontrolled dusting, raw material loss, and contamination of the work area. When the bag is removed from the cutting mechanism, the bag pockets collapse, blocking the flow of product into the receiving bin. Furthermore, the device lacks bag support and alignment before cutting, resulting in deformation of the bag before entering the cutting section, degrading the cutting quality and, consequently, subsequent emptying.

[0010] Patent CN117509231A (published on 06.02.2024, IPC B65G69 / 00) discloses an automatic unpacking system and can be taken as the closest analogue. Thus, within the framework of this patent, the following is disclosed: the system includes an identification mechanism, a manipulator, a frame, a turning mechanism, a bag cutting mechanism and a bag gripping mechanism. The identification mechanism determines the position of the bags with plastic particles, and the manipulator moves the bags with plastic particles. The bag with particles is placed on the turning mechanism, and the turning mechanism, the bag cutting mechanism and the bag gripping mechanism are located on the frame; the turning mechanism is provided with a loading platform, and the loading platform is provided with a positioning mechanism used to fix the bag in a predetermined position. The supporting block is axially connected to the frame. A turning drive is provided on the supporting block.The bag cutting mechanism is equipped with multiple cutters, located below the platform and movable toward the bag on the platform to cut the bag. The bag gripper can move toward the platform and grip the empty bag to transport the empty bag to a predetermined position. A 3D camera is preferably used as the identification mechanism. A striking rod is used to release the remaining material.

[0011] However, the existing solution does not address the issues that arise when handling food products and polypropylene woven bags with sewn seams or bags with separate seams. This system cannot use such bags, as the bottom-cut technology used in this system leaves the seam intact and creates a pocket that can retain up to 20% of the material, which is unacceptable for production. This solution does not prevent bag residue or foreign contaminants from entering the product, as the bag material lies on the surface over which the product flows into the receiving hopper. Also, when unloading woven bags, there is a high risk of bag residue becoming stuck in the hooks of the grippers holding the bag above the receiving hopper. Low emptying rates are also noted for difficult-to-flow materials, as the existing impact rod is insufficient for complete emptying. This solution is not suitable, for example, for unloading sugar, as it requires a special tool.Sugar tends to compact and form lumps. In the presence of such material, there is a risk of stationary knives breaking off and metal getting into the receiving bin, which is critical for any industry.

[0012] SUMMARY OF THE GROUP OF INVENTIONS

[0013] The task, which the claimed group of inventions is aimed at solving, is to increase the efficiency of the process of unloading bags, especially for small-fraction, difficult-to-flow products, by minimizing the residual content of the product in the bag and eliminating the ingress of contaminants, as well as the versatility of the use of the invention due to the driven cutting of the bag and driven forced unloading, the use of a special fork gripper capable of penetrating even into hard seals of the product.

[0014] The technical result achieved through the use of the claimed group of inventions consists in improving the operational characteristics, expressed in the form of an increase in the bag emptying coefficient (less than 0.1% of the remainder) for bulk food products, the versatility of the process for various types of raw material fractions and container materials.

[0015] To achieve the specified technical result, a group of inventions is proposed, including a system and method for automated unloading of bulk raw materials.

[0016] The automated bulk product unloading system includes the following elements:

[0017] - a computing unit 1 that processes the data received through the user interface 1.1, connected via a network interface and cables to a technical vision unit 2 equipped with a 3D camera, an industrial manipulator unit 3 with a gripping device and a de-stuffing unit 4, including a cutting unit equipped with a drive 4.1, a de-stuffing chamber and a receiving bin, as well as an aspiration unit 5 containing a fan with a filter, and is characterized in that:

[0018] - technical vision unit 2, designed with the ability to determine the coordinates of the position of bags on a pallet or container in the coordinate determination module 2.3 using a 3D camera;

[0019] - unloading unit 4, equipped with a shaking unit on bearings with adjustable speed and movement pattern, equipped with drive 4.2;

[0020] - bent lamellas installed on the drive part 4.2 of the receiving hopper and designed with the possibility of performing wave-like movements;

[0021] - a receiving hopper mounted on vibration supports, kinematically connected to the drive of the shaking mechanism 4.2, designed with the possibility of providing shaking at different frequencies;

[0022] - computing unit 1, equipped with a set of modules that provide dynamic control based on data received from the technical vision unit 2 and specified by the operator through the user interface 1.1, including:

[0023] - module for interaction 1.2 and processing of data received from the technical vision unit;

[0024] - industrial manipulator control module 1.3, transmitting a command to the gripper control module 3.3 of the industrial manipulator block 3 to control the speed and trajectory of the industrial manipulator;

[0025] - control module for the unloading chamber 1.4, which changes the movement of the slats and transmits commands to the drive of the shaking mechanism 4.2;

[0026] - cutting unit control module 1.5, allowing you to position the cutting unit;

[0027] - aspiration unit control module 1.6, removing product suspension in the air from the unloading area

[0028] In this case, the technical vision unit 2 can be located on the grip of the industrial manipulator or on a separate bracket located in the unloading area.

[0029] A method for automated unpacking of bulk products, characterized by the following stages:

[0030] - the operator places a pallet with bags into the work area;

[0031] - the operator sets the parameters for unloading bulk products through user interface 1.1;

[0032] - the technical vision unit 2 scans the working area and generates a set of data about the bags;

[0033] - an industrial manipulator, using a gripping device, takes a bag and transfers it to the unloading unit area above the receiving bin;

[0034] - cutting and emptying the bag using cutting and shaking units;

[0035] - throwing an empty bag into the waste area by an industrial manipulator;

[0036] is different in that

[0037] - the formation of bag data includes determining the coordinates of the position of bags in three-dimensional space in the unloading zone;

[0038] - depending on the received data, the manipulator moves along the shortest trajectory to the unloading block;

[0039] - before emptying the bag, the manipulator places it on a leveling table, which lifts the rear edge of the bag to avoid deformation and poor cutting;

[0040] - the cutting unit makes a controlled cut along a given trajectory;

[0041] - the manipulator, depending on the specified parameters and received data, performs a shaking movement;

[0042] - the manipulator moves the bag onto bent lamellas, which exert wave-like effects on the surface of the bag pockets and turn the bag pockets towards the cut part of the bag;

[0043] - the bag with the residual product is knocked out and shaken by a manipulator, lamellas and vibrations of the receiving hopper.

[0044] The system and method described above can improve the efficiency of unloading bags containing bulk solids. High bag emptying rates can be achieved through a power-driven bag cut and a power-driven, forced, multi-stage unloading process.

[0045] BRIEF DESCRIPTION OF GRAPHIC MATERIALS

[0046] The essence of the proposed group of inventions is explained by the following description and accompanying illustrations, which show:

[0047] Fig. 1 - general block diagram of the structure of the system components of automated unloading of bulk products;

[0048] Fig. 2 - block diagram of the structure of the computing unit modules;

[0049] Fig. 3 - block diagram of the structure of the technical vision unit modules;

[0050] Fig. 4 - block diagram of the structure of the modules of the industrial manipulator unit;

[0051] Fig. 5 - block diagram of the structure of the unloading unit and the aspiration unit;

[0052] Fig. 6 - general view of the automated bulk product unloading system;

[0053] Fig. 7 - view of the unloading unit from the cutting mechanism drive side;

[0054] Fig. 8 - view of the unloading block from the drive side of the shaking mechanism;

[0055] Fig. 9 - view of the coordinate determination module.

[0056] IMPLEMENTATION OF A GROUP OF INVENTIONS

[0057] Figure 1 shows a general block diagram of the structure of the system components, which includes a computing unit 1, a technical vision unit 2, an industrial manipulator unit 3, an unloading unit 4, and an aspiration unit 5. The corresponding general view of the system is also presented in Figure 6, which shows blocks 2, 3, 4, 5 with their possible placement in the unloading area.

[0058] The computing unit 1 can be understood as any programmable logic controller containing (not shown in the drawings):

[0059] - at least one processor that processes the incoming information flow;

[0060] - I / O controller;

[0061] - at least one storage device that includes a database;

[0062] - system memory, which stores data for processing software and the operating system, as well as input, output and intermediate data processed by the processor during the operation of the unit.

[0063] A network interface is used to connect system components. All units are also connected via cable ducts (e.g., power, signal, and network cables) and pneumatic lines. A data bus is used to logically connect system elements within the units.

[0064] The computing unit 1 is equipped with a user interface 1.1, which allows the operator to interact with the entire unloading system (see Fig. 2). Unit 1 also contains:

[0065] - module for interaction with technical vision unit 1.2, which receives data from technical vision unit 2;

[0066] - industrial manipulator control module 1.3, which corrects and directs the movement of the manipulator and gripper;

[0067] - unloading chamber control module 1.4, which regulates the process of emptying bags;

[0068] - cutting unit control module 1.5, which regulates the bag cutting process;

[0069] - aspiration unit control module 1.6, which regulates the operation of the fan.

[0070] Computing unit 1 is located in a protective cabinet.

[0071] The vision unit 2 is equipped with a 3D camera, and the unit can be located either on the industrial manipulator itself or on a separate bracket located in the unloading area.

[0072] A stereo or ToF camera can be used as a 3D camera, for example, Hikrobot, Basler, Cognex, Intel or similar.

[0073] Fig. 3 shows a block diagram of the structure of the modules of the technical vision unit 2, containing:

[0074] - Image acquisition module 2.1, which interacts with a 3D camera that scans the work area and bag placement;

[0075] - Pre-processing module 2.2, which analyzes the received visual data;

[0076] - coordinate determination module 2.3 (also shown in Fig. 9), which generates a three-dimensional map with the location of bags on a pallet and recognizes their features;

[0077] - upper level interaction module 2.4, which transfers data to the higher ERP, MES, SCADA system or implements setting parameters from these systems.

[0078] The industrial manipulator is designed for handling and gripping bags. It is a mechanical manipulator with 3.2-mm servo drives. The gripping device is a pneumatic-mechanical or pneumatic-electric device with a feedback system. It consists of a load-bearing frame, drive pins, forks with clamping jaws or a vacuum suction cup, sensors and actuators, and a collision and safety control unit. The industrial manipulator can be installed on the floor or a pedestal, and the gripping device is connected to the industrial manipulator and located on its flange.

[0079] The industrial manipulator unit 3 (Fig. 4) includes a drive control module 3.1, which directs control actions to the industrial manipulator drives 3.2, a gripper control module 3.3, which directs control actions to the gripper drives 3.4.

[0080] The unloading unit 4 (Fig. 5, Fig. 7, Fig. 8) is equipped with a cutting mechanism drive 4.1 and a shaking mechanism drive 4.2. In essence, this is a process unit that contains several elements. The cutting unit 4.3, made in the form of one or a set of disk knives with a drive and a positioning system. As drives 4.1, geared motors with an asynchronous motor are used, connected through a coupling to the shaft on which the knives are mounted. In case of a drive of the shaking mechanism 4.2, a geared motor with a round flange is also used, on which a connecting rod is installed, converting the rotary motion of the drive into reciprocating motion on the lamellas 4.4. The unloading chamber, which is a closed volume with an aspiration pipe, a receiving chute 4.5. The receiving hopper is a storage tank with level sensors. Unloading unit 4 is equipped with a bearing-mounted shaking unit with adjustable speed and motion. Bent slats 4.4 are installed on the drive section of the receiving hopper.These 4.4 lamellas perform a wave-like motion, allowing the bag of bulk product to be completely emptied. The receiving hopper is decoupled from the frame using 4.6 vibration mounts to prevent the vibrations generated by the vibrator motor from being transmitted to the main frame.

[0081] Aspiration unit 5 (Fig. 5) is equipped with aspiration mechanism drive 5.1, which, using a built-in fan with filter, removes dust from the cutting and shaking area. The aspiration unit can be positioned directly above the bag cutting area.

[0082] To disclose the implementation of the group of inventions, an example of unpacking bags of sugar is taken.

[0083] 1. Preparation. A pallet with bags of sugar is placed on the floor, platform, or conveyor section in the loading area.

[0084] The bag has the following characteristics: polypropylene woven with a polyethylene HDPE liner sewn into the neck, grocery, premium grade, GOST 32522-2013. Width 560±1 mm. Height 750±1 mm. Number of threads per 10 cm of fabric: warp: 38±2%, weft: 39±%. Breaking load of the fabric strip, N (kgf): 500. Breaking load of the bottom seam, N (kgf): 250. Neck processing: heat-cut and hemmed with a liner. Bottom seam: single hem, single stitch. Neck seam: Single hem, single stitch

[0085] If necessary, the operator installs it directly or drives up an empty container for the emptied bags, preparing a place for the accumulation of pallets and corrugated cardboard.

[0086] 2. Setup. The operator selects a program on the control panel, including the product name "sugar," the bag type (750x560 PP HDPE), the number of bags remaining, the system speed, and activates the vibrator and shaking module. The system is reconfigured for sugar: the robot control program is changed, the motor control coefficients and speed modes are entered, the final bag shaking subroutines are modified, the cutting trajectories are adjusted for a bag length of 750 mm, and the bag pocket emptying height is changed to 375 mm from the hopper surface.

[0087] 3. Scanning. The machine vision module checks for unauthorized objects within the camera's range. If the scan is successful, it creates a 3D map of the pallet, determines the position, orientation, and size of each sugar bag, and adjusts the robot's movement and the behavior of the cutting, shaking, and vibration units, optimizing the manipulator's trajectory.

[0088] 4. Gripper. The manipulator moves the gripper toward the target bag. The gripper's drive elements enter the sugar bag. The anti-collision unit on the gripper controls the spring deformation. The clamping elements rotate and shift, tensioning the bag material and preventing it from slipping off the gripper.

[0089] 5. Transport and Opening. The manipulator moves along the shortest path each time, calculated based on the position of the new bag to speed up the overall cycle time of the system. The manipulator places the bag on a special leveling table, which supports and lifts the rear edge of the bag. The bag's cutting path is then determined according to the product type (sugar), the specified program, and the bag size. The bag is positioned relative to the cutting mechanism, which performs a controlled cut.

[0090] 6. Unloading. The robot manipulator operates the receiving bin, discharging the bulk of the sugar (90-98%) with a motion corresponding to the product inside the bag. The robot then places the remaining product (0.1-2%), along with the bag, onto curved slats mounted on the drive part of the bin. These slats exert a wave-like effect on the surface of the bag pockets containing the residual product, allowing the pocket containing the remaining material to rotate toward the cut end of the bag. Further emptying of the bag pockets occurs by calculating the distance for their knockout and shaking, using the interaction of the robot and the slats of the shaking unit.

[0091] 7. Bag disposal. The emptied bag is dropped into the waste area by the manipulator.

[0092] The cycle repeats for the next bag. The computer unit controls and coordinates all stages, and the aspiration system removes dust.

[0093] After all the bags are emptied, the manipulator can pick up the empty pallet using a special unit on the gripper or the pallet can move along the conveyor system depending on the system configuration.

[0094] After emptying the cut bags, any remaining sugar is poured onto the scales and the remaining percentage of the 50 kg bag's weight is calculated. The remaining amount is less than 0.1%, which corresponds to less than 50 grams of remaining sugar.

Claims

1. An automated system for unpacking bulk products, including: - a computing unit that processes the data received through the user interface, connected via a network interface and cables to a machine vision unit equipped with a 3D camera, an industrial manipulator unit with a gripping device and a de-stuffing unit, including a cutting unit equipped with a drive, a de-stuffing chamber and a receiving bin, as well as an aspiration unit containing a fan with a filter, characterized in that – the technical vision unit is designed with the ability to determine the coordinates of the position of bags on a pallet or container in the coordinate determination module using a 3D camera; – the unloading unit is equipped with a shaking unit on bearings with adjustable speed and movement pattern, equipped with a drive; – bent lamellas are installed on the drive part of the receiving hopper and are designed to perform wave-like movements; – the receiving bin is installed on vibration supports, kinematically connected to the drive of the shaking mechanism, designed with the ability to provide shaking at different frequencies; – the computing unit is equipped with a set of modules that provide dynamic control based on data received from the machine vision unit and specified by the operator through the user interface, including: – module for interaction and processing of data received from the technical vision unit; – an industrial manipulator control module that transmits a command to the control module of the gripping device of the industrial manipulator block to control the speed and trajectory of movement of the industrial manipulator; – a control module for the unloading chamber, which changes the movements of the slats and transmits commands to the drive of the shaking mechanism; – a cutting unit control module that allows positioning the cutting unit; – aspiration unit control module.

2. The system according to paragraph 1, characterized in that the technical vision unit is located on the grip of the industrial manipulator.

3. The system according to paragraph 1, characterized in that the technical vision unit is located on a separate bracket located in the unloading zone.

4. A method for automated unpacking of bulk products, characterized by the fact that it includes the following stages: – the operator places a pallet with bags into the work area; – the operator sets the parameters for unloading bulk products through the user interface; – the technical vision unit scans the working area and generates a set of data about the bags; – an industrial manipulator, using a gripping device, takes the bag and transfers it to the unloading unit area above the receiving bin; – cutting and emptying the bag using cutting and shaking units; – dumping an empty bag into the waste area using an industrial manipulator, characterized in that – the formation of data on bags includes the determination of the coordinates of the position of bags in three-dimensional space in the unloading zone; – depending on the received data, the manipulator moves along the shortest trajectory to the unloading block; – before emptying the bag, the manipulator places it on a leveling table, which lifts the rear edge of the bag; – the cutting unit makes a controlled cut along a given trajectory; – the manipulator, depending on the specified parameters and received data, performs a shaking movement; – the manipulator moves the bag onto bent lamellas, which exert wave-like effects on the surface of the bag pockets and turn the bag pockets towards the cut part of the bag; – the bag with the residual product is knocked out and shaken by a manipulator, lamellas and vibrations of the receiving bin.

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