Sorting device and method for assembling socks

Abstract

FIELD: folding appliances.SUBSTANCE: invention relates to a device for sorting hosiery used in the home or in laundries. The technical result is achieved by a sock folding device, which is loaded with a stack of different socks, and the output is pairs of identical socks sorted by color, pattern, weight and rolled into a roll.EFFECT: improved performance.14 cl, 11 dwg

Description

[0001] Technical field

[0002] The invention is a device for classifying and sorting hosiery, intended for use both in domestic conditions and in industrial laundries.

[0003] Technology Level

[0004] A "Device for accumulating socks" (patent JPS60228350A) is known, which is aimed at accumulating pre-arranged socks in a storage device for subsequent packaging on another device.

[0005] The "Sorting device for producing socks" (Patent CN214638267U) is known without sorting by sock model.

[0006] A "Sock Sorting Apparatus" (Patent US5456392A) is known, which is designed to operate in a factory environment in conjunction with a main sock production machine and uses a pneumatic pipeline system when sorting socks.

[0007] This invention develops the ideas laid down in the patent “Device and method for sorting socks” (patent RU 2864243C1).

[0008] Disclosure of invention

[0009] The objective of the invention is to automate the folding of socks in domestic conditions.

[0010] The technical result consists in automating the process of sorting and assembling pairs of socks, reducing the processing time for a batch of socks and increasing the accuracy of selecting pairs by color, pattern and size.

[0011] The technical result is achieved by a sorting device consisting of a housing, a gripper, a chute, a scanning zone, a photo scanner, clamps, a clamp mark sensor, a sock presence sensor, a first clamp opening / closing device, a second clamp opening / closing device, a twisting device, a device for securing a pair with thread, a software module, characterized in that it additionally includes a circular conveyor equipped with clamps with individual marks and a rotating mechanism equipped with its own clamp, a sanitary and hygienic processing unit, wherein the gripper is equipped with a weight sensor and can be implemented as a brush gripper, or using Velcro tape, or a collet device, or a pneumatic device with a vacuum suction cup and a pneumatic pump. In addition, the gripper is equipped with a pressure sensor.The sanitizing unit contains ultraviolet lamps and / or an ultrasonic evaporator and / or a sprayer equipped with antibacterial and / or fragrance compounds. Rolling devices can be positioned on two opposite sides of the unit. The bottom of the finished pairs compartment slopes toward the front edge of the tray. The bottom of the finished pairs compartment can also be equipped with a conveyor. The sorting unit is equipped with control buttons and a display.A method for assembling socks involves a gripper removing each sock from a loading chute and moving it onto a circular conveyor. Each sock is weighed by a load cell and scanned by a photo scanner. The resulting data is transmitted to a software module, where each sock is assigned a unique identifier and a digital fingerprint is generated. The software module then compares the fingerprints pair by pair, generates a list of pairs, and controls the circular conveyor to feed the pair to a rolling device, where the socks are rolled and secured with thread, and the finished pair is sent to the finished pairs section. The end of the process is signaled by a color and light indicator. A rotating mechanism rotates the sock around its vertical axis, and the sock is photographed from all sides, capturing up to 360 images of a single sock.If there are more socks in the loading section of the chute than there are clamps, all available clamps are occupied, and pairs of socks are determined on the circular conveyor. As soon as two or more clamps are free, the remaining socks in the chute are placed in the clamps and participate in the next pairing stage. Unpaired socks are transferred to the finished pairs section without twisting. Finished pairs can be sorted by color or weight into different sections of the chute.

[0012] Implementation of the invention

[0013] The figures show projections of the device:

[0014] - Fig. 1, 2 - image of the device from the front and rear projections,

[0015] - Fig. 3 - top view,

[0016] - Fig. 4-1 - sections of the device from different projections,

[0017] - Fig. 8, 9, 10 - images of a gripper equipped with brushes, Velcro tape or a collet mechanism, respectively.

[0018] - Fig. 11 - lifting / lowering the gripper. The sorting device consists of the following units:

[0019] 1. Compartment tray

[0020] 2. Capture

[0021] 3. Sock presence sensor

[0022] 4. Conveyor

[0023] 5. Scanning area

[0024] 6. Photo scanner

[0025] 7. Circular conveyor

[0026] 8. Circular conveyor clamps

[0027] 9. Clamp mark sensor

[0028] 10. First clamp opening / closing device

[0029] 11. Second clamp opening / closing device

[0030] 12. Weight sensor

[0031] 13. Rotary mechanism

[0032] 14. Twisting device

[0033] 15. Twisting device clamp.

[0034] 16. Thread-fixing device for a pair

[0035] 17. Software module

[0036] 18. WiFi Module

[0037] 19. Bluetooth Module

[0038] 20. Power supply

[0039] 21. Spray container

[0040] 22. Ultrasonic (US) evaporator

[0041] 23. Photo scanner lamps

[0042] 24. Control buttons

[0043] 25. Display

[0044] 26. Light-color indication

[0045] 27. Ultraviolet (UV) lamps

[0046] 28. Brush grip

[0047] 29. Pressure sensor

[0048] 30. Velcro tape

[0049] All elements operate sequentially, moving the socks within the device to pair them. All mechanics are controlled by a custom pair recognition algorithm, which uses a neural network and mathematical algorithms to identify colors and patterns.

[0050] Purpose of the sock sorting device elements:

[0051] - tray (1) with a compartment for loading socks for sorting and a separation of finished pairs with an inclined bottom towards the front edge of the tray,

[0052] - The gripper (2) takes socks one at a time from the loading chute (1). The gripper (2) can be designed as a brush gripper mechanism (28) or a gripper with a contact Velcro tape (30) - when transferred to the clamp (8), the conveyor (7) moves away and the sock is separated from the Velcro tape (30). The gripper (2) is also equipped with a pressure sensor (29) and a weighing cell.

[0053] (12). In addition, the gripper can be implemented as a collet gripper (Fig. 10) or a vacuum suction cup. In the latter version, the sorting device is additionally equipped with a pneumatic pump,

[0054] - the device can be equipped with a highly sensitive weighing sensor (12) to determine the size, type of fabric,

[0055] - the sock presence sensor (3) in the loading compartment of the tray (1) checks for the presence of socks,

[0056] - scanning zone (5) is a bright green background (chroma key) to ensure high-quality scanning of socks and to highlight the scan copy from the background,

[0057] - A photo scanner (6) equipped with lamps (23), such as LED lamps, captures sock images for processing their color, pattern structure, shades, and fabric texture. Backlighting provides uniform illumination of the socks for accurate determination of shades, colors, and fabric texture.

[0058] - A mobile circular conveyor (7) of the turret type is equipped with clamps (8) for holding socks. The clamps (8) are equipped with individual marks. The device is equipped with a rotating mechanism.

[0059] (13) for photographing socks from all sides to improve the accuracy of selecting a pair,

[0060] Fixed first (10) and second (11) devices for opening / closing clamps (8). Near each clamp (8) there are marks for use in positioning and sorting, the mark data is read by the mark sensor (9),

[0061] - The rotary mechanism (13) has a gripper. The sock is transferred to the gripper of the rotary mechanism (13), and the sock rotates around the vertical axis, allowing up to 360 images of a single sock to be taken for precise determination of the pattern and texture. After photographing, the sock is clamped by the main clamp (8) of the circular conveyor (7), and the rotary mechanism (13) releases its clamp to accept the next sock.

[0062] - a device for twisting (14) the selected socks into pairs and securing the socks with a thread or tape (16) to prevent them from unwinding. The twisting device (14) can be installed on both sides of the sorting device to increase the speed of twisting into pairs, as well as to distribute the finished pairs into different compartments of the tray (1) by color (colored - in one tray, plain - in another tray, and / or by size and / or other criteria,

[0063] - tray (1) with a compartment for finished pairs, where already folded pairs of socks are stored, has a sloping bottom for rolling finished pairs to the front edge of the tray. In addition, this compartment can be equipped with a conveyor (4) for moving finished pairs to the front wall and evenly distributing them across the tray (1).

[0064] - a software module (17) that controls all mechanical processes and is equipped with a Wi-Fi module (18) for transmitting data to the server and a Bluetooth module (19) for connecting to an application installed on smartphones and two-way exchange of information - monitoring current processes in the sorting apparatus, pausing, delayed start, etc.

[0065] - power supply (20) converts the incoming voltage of 110-240V, 50Hz into a constant voltage from 5V to 20V, necessary for the operation of internal equipment (control of grippers and clamps, conveyor movement, sensors and software module),

[0066] The control buttons (24) are displayed on the display (25) and turn the device on / off, start sorting,

[0067] - a sock sanitary and hygienic processing unit equipped with an ultrasonic evaporator (22) and / or ultraviolet lamps (27). The circular conveyor (7) stops each sock in turn in front of the sanitary and hygienic processing unit and the sock is sprayed with a fragrant composition from a spray container (21) and / or an antibacterial composition in the form of a suspension from the ultrasonic evaporator (22) and / or a fragrant composition in the form of a suspension from the ultrasonic evaporator (22). Each sock is irradiated with ultraviolet lamps (27),

[0068] - The display (25) shows the number of pairs collected and the operating mode with corresponding images and text. In standby mode, it displays the time.

[0069] Light and color indication (26) is made in the form of an RGB LED strip and is located at the bottom of the sorting device and signals in yellow when ready for operation, in green when work is completed, and in red when an error occurs.

[0070] The process of sorting socks consists of the following steps:

[0071] 1. Automatically picks up one sock at a time from the tray,

[0072] 2. Fastening on circular conveyor (7),

[0073] 3. scanning each sock,

[0074] 4. moving along the circular conveyor (7),

[0075] 5. Analyze scanned socks and search for pairs,

[0076] 6. feeding a pair of socks for folding into a pair.

[0077] The user places the socks in the loading tray (1), closes the tray and turns on the sorting device.

[0078] The sock presence sensor (3) in the loading compartment checks for the presence of socks. If there are none, the sorting program stops. If there are socks, the program starts again.

[0079] The circular conveyor (7) moves and brings the free clamp (8) to the sock transfer point. The gripper (2) grips each sock one by one from the loading compartment of the tray (1) and transfers it to the free clamp (8) of the circular conveyor (7). The sock is then transferred from the gripper (2) to the clamp (8).

[0080] Each sock is weighed by a highly sensitive weighing sensor (12).

[0081] The photo scanner lamps (23) turn on and the sock is photographed by the photo scanner (6).

[0082] The grab (2) returns for the next toe.

[0083] In one of the design options, the rotating mechanism (13) rotates the toe around the vertical axis and the toe is photographed from all sides, taking up to 360 photographs of one toe (1 photograph for each degree of rotation).

[0084] Data - sock weight, photo and clip number, are transferred to the software module (17).

[0085] The process is repeated until all clamps (8) on the circular conveyor (7) are occupied or there are no more socks in the loading compartment of the tray (1).

[0086] In one embodiment, if there are more socks in the loading chute than there are clamps (8), then all available clamps (8) are occupied, and pairs of socks are determined on the circular conveyor (7). As soon as two or more clamps (8) are free, the remaining socks in the chute are placed in the clamps (8) and participate in the next pairing stage.

[0087] Then the software module (17) processes the image of each sock, forming its digital print - a multidimensional representation with the ability to analyze the optical characteristics of the textile image and generate, based on them, a unique feature vector characterizing the color distribution, spatial configuration of the pattern and the microstructure of the fabric surface and weight.

[0088] In one embodiment, an image of a sock, along with the clip number (8), is transmitted via a Wi-Fi module (18) over the Internet to a remote server. _On the server, the images are similarly converted into digital prints, after which a paired comparison of the prints is performed with the ability to determine the degree of identity of a pair of products by comparing their feature vectors based on a set of specified parameters. A positive decision on the formation of a pair is made when the color distribution, pattern placement, and texture of the fabric simultaneously correspond to the specified tolerance criteria.

[0089] One implementation uses a neural network trained on a set of sock images labeled with visual features to compare socks and identify pairs.

[0090] While the algorithm for matching pairs based on digital fingerprints is running, socks are processed:

[0091] - antibacterial composition from the spray container (21). The circular conveyor (7) stops each sock in turn in front of the spray container (21), and the spray is sprayed onto the sock.

[0092] - or a flavoring composition from a spray container (21).

[0093] - antibacterial composition in the form of a suspension from an ultrasonic evaporator (22)

[0094] - or a flavoring composition in the form of a suspension from an ultrasonic evaporator (22)

[0095] - ultraviolet lamps (27)

[0096] The matching result—a list of pairs linked to clamp numbers (8)—is transmitted back to the sock sorting device. The software module (17) uses the received data to generate control commands for the circular conveyor (7).

[0097] The circular conveyor (7) is set in motion and sequentially moves the clamps (8) to the area of ​​​​packing socks into pairs to the twisting device (14). The first sock of the pair approaches the twisting device (14). The clamp of the twisting device (15) and the twisting device (14) open, the first sock is brought in, the clamp of the twisting device (15) and the twisting device (14) fix the sock. The clamp (8) releases the sock and the circular conveyor (7) continues to move to transport the second sock of the pair. When the second sock approaches the twisting device (14), the clamp of the twisting device (15) opens, the second sock is brought under the clamp of the twisting device (15) and it fixes the second sock. The clamp (8) of the circular conveyor (7) releases the second sock. The twisting device (14) begins to rotate while simultaneously opening the twisting device clamp (15) and feeding the thread from the fastening device (16).After a few rotations, the twisting device (14) stops, the thread is cut, and the twisting device (14) releases the twisted pair of socks. The finished pair falls into the finished pair compartment of the tray (1) due to gravity.

[0098] The process is repeated until all pairs are ready.

[0099] In one embodiment, the twisting devices (14) are located on two opposite sides and operate simultaneously, accelerating the twisting process of selected pairs. In addition, it is possible to distribute pairs according to different characteristics into different compartments of the tray.

[0100] (1). The pairing process is repeated until there are no socks left on the conveyor (8). If no pairs are found, the unpaired socks fall into the finished pairs compartment without being twisted.

[0101] After the process stops, the machine gives a sound and color signal on the light and color indicator (26) about the end of the process of forming socks into pairs.

[0102] The technical result is a device that is loaded with a stack of different socks, and the output is socks folded in pairs (by color and pattern). The individual socks are fed individually using a gripper.

[0103] (2) and a circular conveyor (7) with clamps (8); pair recognition - by a photo scanner (6) and a software module (17) with a neural network; formation of a finished pair - by a twisting device (14) with fixation with a thread.

[0104] This device frees up a person's time. Experience has shown that treating 10 pairs of hair takes 20-25 minutes.

Claims

1. A sorting device consisting of a housing, a gripper, a tray, a scanning zone, a photo scanner, clamps, a clamp mark sensor, a sock presence sensor, a first clamp opening / closing device, a second clamp opening / closing device, a twisting device, a device for securing a pair with thread, a software module, characterized in that it additionally includes a circular conveyor equipped with clamps with individual marks and a rotary mechanism equipped with its own clamp, a sanitary and hygienic processing unit, and the gripper is equipped with a weighing sensor.

2. A sorting device according to paragraph 1, characterized in that the gripper is made in the form of a brush gripper or using Velcro tape, or a collet device, or a pneumatic device with a vacuum suction cup and a pneumatic pump.

3. The sorting device according to paragraph 1, characterized in that the gripper is equipped with a pressure sensor.

4. The sorting device according to paragraph 1, characterized in that the sanitary and hygienic processing unit contains ultraviolet lamps and / or an ultrasonic evaporator and / or a sprayer equipped with antibacterial and / or aromatic compounds.

5. The sorting device according to paragraph 1, characterized in that the twisting devices are located on two opposite sides of the device.

6. A sorting device according to paragraph 1, characterized in that the bottom of the compartment for finished pairs is made with a slope towards the front edge of the tray.

7. The sorting device according to paragraph 1, characterized in that the bottom of the finished pairs compartment is equipped with a conveyor.

8. The sorting device according to paragraph 1, characterized in that it is equipped with control buttons and a display.

9. A method for assembling socks, comprising the steps of a gripper sequentially removing socks from a tray and moving them onto a circular conveyor, whereby each sock is weighed by a load cell and scanned by a photo scanner, the resulting data is transmitted to a software module, where each sock is assigned a unique identifier and its digital fingerprint is generated, after which the software module compares the fingerprints in pairs, generates a list of pairs, controls the circular conveyor to feed the pair to a twisting device, where the socks are rolled into a roll and secured with a thread, and the finished pair is sent to the finished pairs department.

10. A method for assembling socks using the mechanisms according to paragraph 9, characterized in that the end of the work is signaled by light and color indication.

11. The method for assembling socks according to paragraph 9, characterized in that the rotary mechanism rotates the sock around a vertical axis and the sock is photographed from all sides, taking up to 360 photographs of one sock.

12. The method for assembling socks according to paragraph 9, characterized in that if there are more socks in the loading compartment of the tray than clamps, then all free clamps are occupied, pairs of socks are determined on a circular conveyor, as soon as 2 or more clamps are freed, the remaining socks in the tray take up space in the clamps and participate in the next stage of pair selection.

13. The method for assembling socks according to paragraph 9, characterized in that unpaired socks are placed in the ready-made pairs compartment without being twisted.

14. The method for assembling socks according to paragraph 9, characterized in that the finished pairs are sorted by color and weight characteristics into different compartments of the tray.

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