Block sorting method and block sorting system

Abstract

A block sorting method, comprising: guiding blocks to be sorted to a material falling position for an unsupported falling motion; scanning said blocks at a scanning area on a falling trajectory of the unsupported falling motion; on the basis of the scanning, recognizing blocks to be separated among said blocks and determining a separation execution mechanism (150) for separating the blocks to be separated; and instructing the determined separation execution mechanism to separate the blocks to be separated, wherein the separation execution mechanism comprises at least two stages of separation execution mechanisms which are arranged on the falling trajectory and at different heights below the scanning area, and the stages of separation execution mechanisms are suitable for processing different particle size ranges. By arranging the at least two stages of separation execution mechanisms which are suitable for processing different particle size ranges, the particle size processing range of block sorting is widened. Also disclosed is a block sorting system (100).

Description

Block sorting method and block sorting system

[0001] This application is based on and enjoys the priority of Chinese patent application No. 2023113483432, the entire contents of which are incorporated herein by reference. Technical Field

[0002] The present disclosure generally relates to the field of material sorting machines, and more particularly to mining machinery and equipment. More particularly, the present disclosure relates to a block sorting method and a block sorting system. Background Art

[0003] Mining machinery and equipment involve a mass sorting system for sorting lumps of material such as ore. This system typically consists of a feeding mechanism, a transmission mechanism, a detection mechanism, a signal processing mechanism, and a separation actuator. Currently, commonly used mass sorters can only sort lumps within a certain size range. Each sorter typically has strict limitations on the size range of the feed material, with the upper limit typically being 5 to 6 times the lower limit, such as 8mm to 40mm, 10mm to 60mm, and 50mm to 300mm.

[0004] When the particle size range is too large, the same separation actuator may not have sufficient separation force for larger particle size objects within the particle size range, or may have low separation accuracy for smaller particle size objects.

[0005] In view of this, there is an urgent need to provide a block sorting solution that can meet the needs of sorting blocks with a wide particle size range while ensuring separation accuracy.

[0006] Summary of the Invention

[0007] In order to solve one or more of the technical problems mentioned above, the present application proposes a block sorting method and a block sorting system using the method, which can increase the particle size range of the blocks to be sorted and ensure the separation accuracy within a large particle size range.

[0008] According to a first aspect of the present invention, a method for sorting blocks is provided, characterized in that the method comprises: guiding the blocks to be sorted to a material drop location for unsupported falling motion; scanning the blocks to be sorted at a scanning area on the falling trajectory of the unsupported falling motion; identifying the blocks to be separated in the blocks to be sorted based on the scanning, and determining a separation execution mechanism for performing separation on the blocks to be separated; and instructing the determined separation execution mechanism to perform separation on the blocks to be separated; wherein the separation execution mechanism comprises at least two levels of separation execution mechanisms arranged on the falling trajectory at different heights below the scanning area, and each level of separation execution mechanism corresponds to a different processing particle size range.

[0009] In an optional embodiment, the determining of the separation execution mechanism that will perform separation on the to-be-separated blocks includes: determining a separation execution mechanism that is suitable for the to-be-separated blocks based on the particle size of the to-be-separated blocks as the determined separation execution mechanism.

[0010] In an optional embodiment, the determination of the separation execution mechanism that will perform separation on the object to be separated further includes: determining whether the separation operation can be performed when the object to be separated falls to the suitable separation execution mechanism; and in the case that the separation operation cannot be performed when the object to be separated falls to the suitable separation execution mechanism, using the next-level separation execution mechanism of the suitable separation execution mechanism as the determined separation execution mechanism.

[0011] In an optional embodiment, the determining whether the separation operation can be performed when the object to be separated falls to the suitable separation execution mechanism includes: determining whether the time difference between the time when the suitable separation execution mechanism receives the information of the object to be separated and the start time of scanning the object to be separated is greater than a predetermined time difference Δt', wherein the predetermined time difference Δt' is the falling time of the object to be separated from the scanning area to the suitable separation execution mechanism; and if the time difference is greater than the predetermined time difference Δt', determining that the separation operation cannot be performed when the object to be separated falls to the suitable separation execution mechanism.

[0012] In an optional embodiment, the determining whether the separation operation can be performed when the object to be separated falls to the suitable separation execution mechanism includes: determining whether the difference between the time when the object to be separated reaches its suitable separation execution mechanism and the current time exceeds a set threshold, wherein the current time is the time when the current object to be separated is processed, and the set threshold is determined according to the transmission time of the indication and the response time of the separation execution mechanism; and if the set threshold is exceeded, determining that the separation operation cannot be performed when the object to be separated falls to the suitable separation execution mechanism.

[0013] In an optional embodiment, the at least two levels of separation actuators are arranged from high to low on the falling trajectory in the order of processed particle sizes from small to large.

[0014] In an optional embodiment, the vertical distance between each level of separation actuator and the falling point of the material is determined according to the upper limit of the particle size range processed by it. The larger the upper limit of the particle size, the longer the vertical distance.

[0015] In an optional embodiment, the at least two-stage separation actuator is selected from any one of the following or a combination thereof: a blowing mechanism or a push plate mechanism.

[0016] According to a second aspect of the present invention, a block sorting system is provided, characterized in that it comprises: a feeding mechanism, a detection mechanism, a control mechanism and at least two levels of separation execution mechanisms, wherein: the feeding mechanism is used to guide the blocks to be sorted to the material falling place for unsupported falling movement; the detection mechanism is arranged on the falling trajectory of the unsupported falling movement, and is used to scan the blocks to be sorted; the control mechanism identifies the blocks to be separated in the blocks to be sorted based on the scanning of the detection mechanism, determines the separation execution mechanism that will perform separation on the blocks to be separated, and issues instructions to the determined separation execution mechanism; and the at least two levels of separation execution mechanisms are arranged at different heights on the falling trajectory and below the detection mechanism, each level of separation execution mechanism is suitable for a different processing particle size range, and is used to perform separation on the blocks to be separated according to the instructions of the control mechanism. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The above and other objects, features and advantages of the exemplary embodiments of the present disclosure will become readily understood by reading the detailed description below with reference to the accompanying drawings. In the accompanying drawings, several embodiments of the present disclosure are shown in an illustrative and non-limiting manner, and the same or corresponding reference numerals represent the same or corresponding parts, wherein:

[0018] FIG1a shows a schematic structural diagram of a belt-type block sorting system;

[0019] FIG1b shows a schematic structural diagram of a quasi-free-fall object sorting system;

[0020] FIG2 shows a schematic structural diagram of a block sorting system according to an embodiment of the present disclosure;

[0021] 3a-3b are exemplary schematic diagrams of distance design from detection and identification to separation execution according to an embodiment of the present disclosure;

[0022] FIG4 shows an exemplary flow chart of a block sorting method according to an embodiment of the present disclosure;

[0023] FIG5 shows a block sorting system according to some other embodiments of the present disclosure; and

[0024] FIG6 shows a schematic diagram of a height adjustment mechanism according to some embodiments of the present disclosure. DETAILED DESCRIPTION

[0025] The following will clearly and completely describe the technical solutions in the embodiments of this disclosure in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of this disclosure, not all of them. Based on the embodiments of this disclosure, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of this disclosure.

[0026] It should be understood that the terms “include” and “comprising” used in the specification and claims of the present disclosure indicate the presence of described features, integers, steps, operations, elements and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or collections thereof.

[0027] It should also be understood that the terminology used in this disclosure is for the purpose of describing specific embodiments only and is not intended to limit the disclosure. As used in this disclosure and the claims, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. It should be further understood that the term "and / or" as used in this disclosure and the claims refers to any and all possible combinations of one or more of the associated listed items, including and including these combinations.

[0028] As used in this specification and claims, the term "if" can be interpreted as "when" or "upon" or "in response to determining" or "in response to detecting," depending on the context. Similarly, the phrase "if it is determined" or "if [described condition or event] is detected" can be interpreted as meaning "upon determination" or "in response to determining" or "upon detection of [described condition or event]" or "in response to detecting [described condition or event]," depending on the context.

[0029] The specific embodiments of the present disclosure are described in detail below with reference to the accompanying drawings.

[0030] FIG1 a shows a belt-type block sorting system known to the applicant. As shown in the figure, the block sorting system 100 includes a feeding mechanism 110 , a transmission mechanism 120 , a detection mechanism 130 , a control mechanism 140 and a separation execution mechanism 150 .

[0031] The feeding mechanism 110 is used to feed the material to be sorted into the conveying mechanism 120. The material to be sorted can be ore or other materials. The feeding mechanism 110 can include, for example, a vibrating distributor that has the functions of vibrating and screening the material to disperse the material into the conveying mechanism 120.

[0032] The transmission mechanism 120 is used to transport the blocks to be sorted fed by the feeding mechanism 110. The transmission mechanism 120 can be, for example, a conveyor belt or a chute. As shown in the figure, the transmission mechanism 120 can be arranged below the feeding mechanism 110, and the blocks to be sorted fall from the discharge port of the feeding mechanism 110 to the left end of the transmission mechanism 120 and are transported to the right. Finally, the blocks to be sorted can be thrown out from the output end (i.e., the right end) of the transmission mechanism 120 at an initial speed. Due to the friction between the transmission mechanism 120 and the blocks to be sorted, the movement speed and direction of the blocks to be sorted gradually become consistent with the transmission mechanism 120, reaching a stable state, and being dispersed and spread on the belt or chute, and then detaching from the transmission mechanism at the right end of the transmission mechanism 120, being thrown out at an initial speed, and moving along a parabolic motion trajectory.

[0033] The detection mechanism 130 is used to inspect the blocks to be sorted conveyed by the conveyor mechanism 120 to determine whether they are blocks to be separated or blocks that do not require separation. Blocks to be separated are blocks that will be separated by the separation actuator 150. Blocks to be separated can be desired blocks or undesired blocks, as long as they can be sorted. Specifically, as shown in the figure, the detection mechanism 130 can be positioned above the conveyor mechanism 120 to capture images of the blocks to be sorted to determine whether they are blocks to be rejected or blocks that do not require rejection. For example, the detection mechanism 130 can use various spectral techniques, such as X-rays or infrared, to image the blocks to be sorted to obtain analytical images of the blocks. Furthermore, the detection mechanism 130 can capture images of the blocks to be sorted conveyed by the conveyor mechanism 120 to obtain physical information about the blocks to be rejected, such as size, location, and weight.

[0034] The control mechanism 140 is used to control the separation execution mechanism 150 to perform the separation action based on the detection results of the detection mechanism 130. Specifically, the control mechanism 140 can determine the object to be separated based on the image collected by the detection mechanism 130, and further obtain the physical information of the object to be separated. Then, based on the physical information of the object to be separated, the various parameters of the separation execution mechanism 150 that will perform the separation operation on the object to be separated are determined. Finally, the control mechanism 140 instructs the separation execution mechanism to perform separation on the object to be separated. The control mechanism can generally include a processor (such as PLC, MCU, CPU, etc.), a memory, and electronic components connected to the processor, etc. These components are well known to those skilled in the art and will not be described in detail here. The separation execution mechanism 150 can be, for example, a blowing device to blow the object to be separated away from its original motion trajectory to achieve separation from other objects that have not been blown.

[0035] Figure 1a shows a belt-type separator. The ore is conveyed by a belt, achieving a stable initial velocity, and then undergoes parabolic motion from the output end. The detection mechanism is located above the belt, and the separation actuator is arranged along the parabolic trajectory. However, this belt-type separator requires a long conveyor belt, which occupies a large amount of equipment space and is not conducive to cost reduction. In view of this, the applicant has provided another quasi-free-fall separator.

[0036] FIG1 b shows a schematic structural diagram of a block sorting system provided by an embodiment of the present disclosure. As shown in the figure, the block sorting system includes a feeding mechanism 3 , a detection mechanism 4 , a control mechanism 5 , a separation execution mechanism 6 and a receiving mechanism 7 .

[0037] The feeding mechanism 3 can be a vibrating feeder, including a feeding part 31 and a vibration source part 32 connected to the feeding part 31. The vibration source part 32 can be a vibration motor or an electromagnetic vibrator. During operation, the ore is transported from the material bin to be inspected to the feeding mechanism 3 through a belt conveyor (not shown). After the ore falls onto the feeding part 31, the vibration source part 32 generates vibration and drives the feeding part 31 to vibrate, forcing the ore on the feeding part 31 to jump forward evenly and stably until it reaches the discharge port at the front end of the feeding part 31. At the discharge port (i.e., where the material falls), the ore falls evenly along the discharge port to the sorting and identification area below in a quasi-free fall state.

[0038] The detection mechanism 4 is arranged below the feeding part 31. The detection mechanism 4 can be a camera or an X-ray detection mechanism. In the example of Figure 1, the detection mechanism 4 is an X-ray detection mechanism, which includes a transmitter 41 and a receiver 42. The space between the transmitter 41 and the receiver 42 is located below the discharge port, forming a scanning area for scanning the material falling from the discharge port. The transmitter 41 may include at least one transmitting source, and the receiver 42 may include a plurality of receiving units. When the ore falling from the discharge port passes through the scanning area, the transmitter 41 emits fan-shaped distributed X-rays, and the X-rays pass through the ore and reach the receiver 42. The receiver 42 generates information for detecting the type or quality, profile / particle size, etc. of the ore based on the received X-rays.

[0039] The control mechanism 5 is used to identify the type / quality, profile / particle size, etc. of the ore based on the information obtained by the scanning of the detection mechanism 4 to determine whether a separation operation is required for the ore. It is understood that the ore to be separated can be a desired block or an undesired block, as long as the blocks can be separated. When it is determined that a separation operation is required, a separation execution instruction is issued to the separation execution mechanism 6. The control mechanism 5 may include a processing unit that is communicatively connected to the detection mechanism 4 and the separation execution mechanism 6 to transmit information. The control mechanism 5 can be located at an appropriate location in the block sorting system as needed.

[0040] The separation actuator 6 is arranged on the ore falling path and below the scanning area, and is used to perform separation operations on the ore to be separated according to the instructions of the control mechanism 5. The separation actuator 6 can be a blowing mechanism or a push plate mechanism, or any actuator that meets the separation function. The specific operation can be determined according to the volume, weight, etc. of the objects to be separated. For example, when the ore to be separated is a large-volume and heavy-weight ore, a push plate mechanism can be used as the separation actuator. Conversely, if the ore to be separated is a small-volume and light-weight ore, a blowing mechanism can be used as the separation actuator. The example of Figure 1 shows a blowing mechanism as a separation actuator, which selectively blows the passing ore according to the instructions of the control mechanism 5, so that the blown ore deviates from the original falling trajectory, thereby separating it from other ores that have not been blown and continue to move along the original falling trajectory.

[0041] The receiving mechanism 7 is located below the separation actuator 6 and is used to receive two types / qualities of ore and store or release them in blocks. In the example of Figure 1, the receiving mechanism 7 may include a partition to divide the receiving space into two spaces: one for receiving ore that has not been activated by the separation actuator 6, and the other for receiving ore that has been activated by the separation actuator 6 (for example, by blowing or beating).

[0042] Figure 1b shows a quasi-free-fall separator. Ore passes through a vibrating feeder and falls unsupported from the drop point. Because this motion may have an initial velocity, it is also referred to as quasi-free-fall in this context. This quasi-free-fall separator eliminates the need for a conveyor belt, saving space. Furthermore, both the detection mechanism and the separation actuator are located along the trajectory of the unsupported drop.

[0043] As mentioned in the background, existing separators typically have strict limits on the particle size range of the incoming material. When the particle size range is too large, the same separation actuator will either be insufficient for separating larger particles within the particle size range, or have low separation accuracy for smaller particles.

[0044] In view of this, and taking into account the advantages and disadvantages of the two aforementioned sorting machine structures, the disclosed embodiment is based on an improvement of the quasi-free-fall block sorting system shown in FIG1b , by configuring at least two separation actuators to increase the particle size processing range of the block sorting system. Furthermore, in view of the structural characteristics of the quasi-free-fall sorting machine, such as the fact that the initial velocity of the falling block may not be so stable and the falling posture may also be unstable, the detection mechanism and the separation actuator are both arranged on the motion trajectory of the unsupported falling motion. These factors will affect the selection of the separation actuator. Therefore, in some embodiments, the installation position of the separation actuator is also carefully designed to ensure the accuracy of separation within a large particle size range.

[0045] 2 shows a schematic structural diagram of a block sorting system 20 according to an embodiment of the present disclosure. As shown in the figure, the block sorting system 20 includes a feeding mechanism 21, a detection mechanism 22, a control mechanism 23, and a separation execution mechanism 24.

[0046] Feeding mechanism 21 is used to guide the materials to be sorted to the material drop location, where they fall unsupported, i.e., in a quasi-free-fall state, potentially with a certain initial velocity. Detection mechanism 22 is arranged along the trajectory of this unsupported fall and is used to scan the falling materials to be sorted. The structure, function, and role of feeding mechanism 21 and detection mechanism 22 are similar to those of feeding mechanism 3 and detection mechanism 4 in Figure 1b. The above description is equally applicable and will not be repeated here.

[0047] Unlike the object sorting system of FIG1b , in the disclosed embodiment, the separation actuator 24 includes at least two stages of separation actuators, arranged at different heights below the detection mechanism 22 and along the falling trajectory of the objects to be sorted. FIG2 exemplarily illustrates two separation actuators 241 and 242 . In these embodiments, the control mechanism 23 is used to identify the objects to be separated from the objects to be sorted based on the scanning by the detection mechanism 22, determine the separation actuator that will perform separation on the objects to be separated, and issue instructions to the determined separation actuator. The corresponding separation actuator separates the objects to be separated in response to the instructions of the control mechanism.

[0048] Each level of separation actuator can be suitable for processing different particle size ranges. The processing particle size ranges of each level of separation actuator together constitute the processing particle size range of the object sorting system 20. Therefore, by setting up multiple levels of separation actuators, the particle size range that the object sorting system can process can be increased.

[0049] In some embodiments, the number of stages of the separation actuator can be determined based on the particle size range that the object sorting system needs to process. Furthermore, the processing particle size range of each stage of the separation actuator can be determined based on the configuration of the separation actuator that can be used. For example, when the particle size range is 30mm to 300mm, that is, 10 times, a two-stage separation actuator can be used to process objects with particle sizes ranging from 30mm to 150mm and 150mm to 300mm, respectively. For another example, when the particle size range is 10mm to 600mm, that is, 60 times, a three-stage separation actuator can be used to process objects with particle sizes ranging from 10mm to 50mm, 50mm to 300mm, and 300mm to 600mm, respectively.

[0050] In some embodiments, the separation actuators at each level can be of the same type or of different types. For example, the multi-stage separation actuators can all be blowing mechanisms, or all be push plate mechanisms, or a combination of blowing mechanisms and push plate mechanisms, or a combination of any separation actuators that can meet the separation function. Those skilled in the art will understand that the specific number of stages of separation actuators required and the processing particle size range and mechanism type of each stage can be adjusted and configured by those skilled in the art based on actual needs and experience, and the embodiments disclosed herein are not limited in this respect. In addition, there may also be a small overlap between the processing particle size ranges suitable for the separation actuators at each level.

[0051] In some embodiments, the control mechanism 23 is further used to determine a separation actuator suitable for the object to be separated as the aforementioned separation actuator determined based on the particle size of the object to be separated. Specifically, according to the particle size of the object to be separated, the separation actuator corresponding to the processing particle size range into which it falls is selected. For example, assuming that two-stage separation actuators are configured to process objects with particle sizes ranging from 30mm to 150mm and 150mm to 300mm respectively, when the particle size of the object to be separated is 200mm, it falls within the particle size range of 150mm to 300mm, then the separation actuator corresponding to the particle size range is selected to perform the separation operation on the object to be separated. By determining a separation actuator suitable for the object to be separated based on the particle size of the object to be separated, that is, selecting a separation actuator that falls within its processing particle size range to perform the separation action, more accurate separation can be performed, avoiding the use of an unmatched separation actuator to perform separation, thereby improving the separation accuracy.

[0052] The applicant also noted that for a quasi-free-fall sorting system, objects are usually fed directly by a vibrating feeder, and their initial velocity may be unstable, so errors are easily generated in the judgment of the separation execution time and / or the falling position of the objects. Moreover, the speed of the objects will become faster and faster during the falling process, and the higher the speed, the lower the accuracy of the separation execution. Therefore, in the design of the object sorting system, the distance from detection and identification to separation execution is required to be as short as possible. If the distance is large, the error when the objects pass through the separation execution mechanism will be relatively large, reducing the accuracy of the separation execution and affecting the performance of the equipment. In comparison, in a belt sorting machine, since the detection mechanism is arranged above the transmission belt and the belt transmission has a certain horizontal length, there is usually enough time to identify and judge the sorted objects. In addition, in the belt sorting machine, the objects move in a parabolic motion with a relatively stable initial velocity. The motion trajectory is longer than that of the quasi-free fall type. The separation actuator can be arranged on a parabolic motion trajectory that is relatively long in the horizontal direction and relatively short in the vertical direction. Therefore, there is no need to consider the above factors in the quasi-free fall sorting system.

[0053] 3a-3b are exemplary schematic diagrams of distance design from detection and recognition to separation execution according to an embodiment of the present disclosure.

[0054] As shown in Figure 3a, the objects to be sorted are guided by the feeding mechanism to the material drop area 301, where they undergo an unsupported fall motion, potentially with an initial velocity v0, thus also referred to as quasi-free fall. During this fall, the objects to be sorted sequentially pass through the detection mechanism and the separation actuator. It should be understood that v0 is a directional vector, which can be either vertically upward or vertically downward.

[0055] As shown in the figure, the vertical distance from the material drop point 301 to the detection mechanism 302 is set to h1, and the vertical distance from the material drop point to the separation actuator 303 is set to h2; the falling time of the object to be sorted from the material drop point to the detection mechanism 302 and the falling time of the object from the material drop point to the separation actuator 303 are t1 and t2 respectively. The following formula represents the relationship between the falling time and the falling distance:

[0056] Assuming that the time difference between the object moving from the detection mechanism to the separation actuator is Δt, the solution to the time difference Δt is as follows:

[0057] As can be seen from the above formula 3, for a specific or particular sorting device, the vertical distance h1 from the material drop point to the detection mechanism and the vertical distance h2 from the material drop point to the separation actuator are fixed values, and h2>h1. v0 is the initial velocity brought by the feeding mechanism (such as a vibrating feeder), which has uncontrollable volatility. The relationship between this volatility and the accuracy of object separation is shown in the above formula 3. In other words, the smaller the volatility of v0, the smaller the error in the estimated time difference Δt for detecting separation execution. The volatility of v0 can be reduced by selecting a suitable vibrating feeder.

[0058] On the other hand, when v0 is constant, the closer the vertical distance h1 from the material falling point to the detection mechanism and the vertical distance h2 from the material falling point to the separation actuator are, the smaller the speed change and the smaller the error of the separation actuator in performing the separation action.

[0059] However, the distance between h1 and h2 cannot be infinitely close, as analysis, identification, and separation can only be performed after the object has been scanned. In other words, the upper limit of the processing granularity determines the lower limit of the distance between the detection mechanism and the separation actuator. For example, assuming the minimum processing granularity is a and the maximum processing granularity is b, the lower limit of the distance between the detection mechanism and the separation actuator depends on b. In some implementations, the lower limit of the distance between the detection mechanism and the separation actuator can be set to b.

[0060] Based on the above principles, in the embodiment disclosed herein, the vertical distance between each stage of the multi-stage separation actuator and the point where the material falls can be determined according to the upper limit of the particle size range it processes. The larger the upper limit of the particle size, the longer the vertical distance.

[0061] It will be appreciated that when the height of the separation actuator is determined according to the upper limit of each particle size range, the separation actuator processing smaller particle sizes is closer to the detection mechanism, while the separation actuator processing larger particle sizes is further away from the detection mechanism. Therefore, in some embodiments, the multi-stage separation actuators provided in the object sorting system are arranged from high to low along the falling trajectory of the object, in the order of the particle sizes processed from small to large, thereby minimizing the distance between each stage of the separation actuator and the detection mechanism and improving separation execution accuracy.

[0062] FIG3 b shows an exemplary two-stage separation actuator. The vertical distance from the first-stage separation actuator 3031 to the material falling point is h. 21 The vertical distance from the second-stage separation actuator 3032 to the material falling point is h 22 .h 21 Determined according to the upper limit of the particle size range that the first-stage separation actuator is suitable for processing, h 22 It is determined based on the upper limit of the particle size range that the second-stage separation actuator is suitable for processing. Obviously, h 21 <h 22 , that is, the first-stage separation actuator is suitable for processing smaller-sized objects, while the second-stage separation actuator is suitable for processing larger-sized objects. Therefore, by providing multiple stages of separation actuators and arranging the distance between each stage of separation actuators and the detection mechanism as close as possible, separation accuracy can be maintained while increasing the range of processed particle sizes.

[0063] For example, in Figure 3b, the top of the falling small elliptical block is essentially aligned with the top of the large hexagonal block, indicating that both have just been scanned. After a relatively fixed data processing period, the block information reaches the first-stage separation actuator 3031 and the second-stage separation actuator 3032, indicating the actual falling state of the blocks. As can be seen from the figure, the first-stage separation actuator 3031 is suitable for separating small elliptical blocks, while the second-stage separation actuator 3032 is suitable for separating large hexagonal blocks.

[0064] As mentioned above, the processing size ranges suitable for each separation mechanism may overlap slightly. In these embodiments, when there is a slight overlap between the processing size ranges suitable for each separation mechanism, the objects to be separated may fall into two processing size ranges simultaneously. In this case, a separation mechanism closer in height to the detection mechanism can be selected to minimize the distance between detection and separation execution, thereby improving separation accuracy.

[0065] In addition, considering that the data of the object may not be processed when it reaches its appropriate separation actuator due to the large amount of recognition calculation and high load of the control mechanism, resulting in missed separation, in the embodiment of the present disclosure, supplementary operations can be performed on the next-level separation actuator to improve the overall efficiency of the equipment.

[0066] Specifically, the control mechanism can determine whether the separation operation can be performed when the object to be separated falls to its suitable separation execution mechanism; and in response to determining that the separation operation cannot be performed when the object to be separated falls to its suitable separation execution mechanism, the next-level separation execution mechanism of the suitable separation execution mechanism is determined as the separation execution mechanism that actually performs the separation action.

[0067] For example, assume a two-stage separation actuator is configured, with the first stage processing objects with a particle size range of 30mm to 150mm, and the second stage processing objects with a particle size range of 150mm to 300mm. When the particle size of the object to be separated is 40mm, it falls within the particle size range of the first-stage separation actuator, which means that the first-stage separation actuator is the separation actuator suitable for the current object to be separated. However, when the control mechanism processes this object, it finds that due to the heavy processing load, the first-stage separation actuator is unable to perform the separation operation on it in a timely manner. For example, the control mechanism is unable to issue instructions to the first-stage separation actuator in a timely manner. In this case, the control mechanism can adjust to issue instructions to the next-stage separation actuator, that is, the second-stage separation actuator, to make up for the missed object.

[0068] The control mechanism can determine whether the separation operation can be performed when the to-be-separated object falls to its appropriate separation execution mechanism in a variety of ways.

[0069] In some embodiments, determining whether a separation operation can be performed when a block to be separated falls onto a suitable separation actuator can include: determining whether the time difference between the time when the suitable separation actuator receives information about the block to be separated and the time when scanning of the block to be separated begins is greater than a predetermined time difference Δt', where the predetermined time difference Δt' is the time it takes for the block to be separated to fall from the scanning area to the suitable separation actuator; and if the time difference is greater than the predetermined time difference Δt', determining that a separation operation cannot be performed when the block to be separated falls onto its suitable separation actuator. In these embodiments, the control mechanism can be distributed and, in addition to the processing unit for identification, can also include multiple controllers or control units distributed across various separation actuators. The controllers or control units at the separation actuators can compare the time when the information about the block to be separated is received with the time when scanning of the block to be separated begins. If the time difference between the two is greater than the predetermined time difference Δt', it indicates that the block to be separated has passed through the suitable separation actuator, and an operation on it has been missed. In this case, the current separation actuator can notify its next-level separation actuator to perform a complementary operation on the missed block. It can be understood that when the sorting system has been configured, the positions of the detection mechanism and each separation actuator are fixed, so the above-mentioned predetermined time difference Δt' can be estimated, for example, using the previous formula 3. When estimating the predetermined time difference Δt', the initial velocity v0 in formula 3 can have multiple values. In one implementation, the feeding mechanism (such as a vibrating feeder) is controlled as much as possible so that the initial velocity of the object approaches 0, so v0=0 can be set to calculate the predetermined time difference Δt'. In another implementation, the initial velocity given to the object by the feeding mechanism can also be statistically analyzed, and the median or average value is taken to calculate the predetermined time difference Δt'.

[0070] In other embodiments, determining whether the separation operation can be performed when the object to be separated falls to the appropriate separation execution mechanism may include: determining whether the difference between the time when the object to be separated reaches its appropriate separation execution mechanism and the current time exceeds a set threshold. The current time is the time when the current object to be separated is processed. The set threshold can be determined, for example, based on the indicated transmission time and the response time of the separation execution mechanism. If it exceeds the set threshold, it means that there is enough time to instruct the appropriate separation execution mechanism to perform the separation operation. If it does not exceed the set threshold, it means that it is impossible to instruct the separation execution mechanism to perform the separation operation in time and it is necessary to adjust to the next level of separation execution mechanism. In these embodiments, the control mechanism can be centralized, for example, the processing unit therein centrally executes the identification of the object to be separated and determines the final separation execution mechanism. At this time, if the control mechanism determines that the appropriate separation execution mechanism is too late to perform the separation operation, it can directly notify its next level of separation execution mechanism to perform a supplementary operation on the missed objects.

[0071] The time t2 at which the object to be separated reaches its appropriate separation actuator can be determined, for example, by adding the time t1 at which the object reaches the detection mechanism to the estimated time difference Δt for detecting the separation. For a specific object sorting device, the distance between the detection mechanism and each level of the separation actuator is fixed, and the initial feeding speed of the vibrating feeder can be controlled within a certain range. Therefore, the time difference for detecting the separation execution at each level can be estimated based on the above formula 3.

[0072] It can be understood that when there are more than two levels of separation actuators, if it is determined that it is impossible to issue an instruction before the object to be separated falls to its appropriate separation actuator, it is also possible to directly determine the separation actuator that can perform timely supplementary operations on the object to be separated based on the time when the object to be separated arrives at the detection mechanism, so as to avoid the situation where the next level of separation actuator is also unable to perform supplementary operations in time. For example, assuming that three levels of separation actuators are configured, the first level processes a particle size range of 10mm to 50mm, the second level processes a particle size range of 50mm to 300mm, and the third level processes a particle size range of 300mm to 600mm. When the particle size of the object to be separated is 40mm, it falls within the particle size range of the first level separation actuator, that is, the first level separation actuator is a separation actuator suitable for the current object to be separated. However, when the control mechanism encounters this object, it discovers that due to the heavy processing load, it is unable to issue instructions to the first-stage separation actuator in a timely manner. Furthermore, the control mechanism determines the next-stage separation actuator based on the time when the object to be separated arrives at the detection mechanism. This means that the second-stage separation actuator is unable to perform a follow-up operation in a timely manner, but the third-stage separation actuator is able to process the object in a timely manner. In this case, the control mechanism can directly send instructions to the third-stage separation actuator to perform the separation operation on the object to be separated.

[0073] Furthermore, the particle size ranges handled by each stage of the separation actuators allow the upstream separation actuator to cover a wider range. For example, if the particle size range of the objects to be sorted is 30mm to 300mm, two stages of separation actuators are used to handle objects ranging from 30mm to 150mm and 150mm to 300mm, respectively. The particle size range of the first-stage separation actuator is 30mm to 150mm, with an upper-to-lower ratio of approximately 5; the particle size range of the second-stage separation actuator is 150mm to 300mm, with an upper-to-lower ratio of approximately 2. That is, within the entire 30mm to 300mm particle size range of the objects to be sorted, the upstream first-stage separation actuator handles a larger portion of the particle size range, while the downstream second-stage separation actuator handles a smaller portion.

[0074] This is because, in a two-stage separation actuator setup, the second-stage separation actuator is already the last stage. If it becomes overloaded and cannot quickly separate the appropriate objects, there is no next-stage separation actuator to take over. Therefore, by having the upstream separation actuator cover a wider range of particle sizes, it is possible to prevent the downstream, especially the last stage, separation actuator from being unable to perform separation operations in a timely manner.

[0075] The above description uses a two-stage separation actuator as an example, but the same applies to cases involving more stages. For example, when the particle size range is 10mm to 600mm, or 60 times, a three-stage separation actuator can be used to process objects with particle size ranges of 10mm to 50mm, 50mm to 300mm, and 300mm to 600mm, respectively. Specifically, the particle size range of the first-stage separation actuator is 10mm to 60mm, with an upper-to-lower ratio of approximately 6; the particle size range of the second-stage separation actuator is 50mm to 300mm, with an upper-to-lower ratio of approximately 6; and the particle size range of the third-stage separation actuator is 300mm to 600mm, with an upper-to-lower ratio of approximately 2.

[0076] By having the first and second separation actuators on the upstream side cover a larger granularity range, it is possible to avoid the last separation actuator, ie the third separation actuator, from being burdened with the process and thus failing to perform the separation operation in a timely manner.

[0077] The above describes the object sorting system provided by the embodiment of the present disclosure. Accordingly, the embodiment of the present disclosure also provides a corresponding object sorting method.

[0078] FIG4 shows an exemplary flow chart of a block sorting method 400 according to some embodiments of the present disclosure.

[0079] As shown in the figure, at step S410, the objects to be sorted are guided to a material drop area for unsupported falling motion. In one implementation scenario, the above-described object sorting method is applied to a chute-type sorting device. The chute-type sorting device includes a feed inlet and a vibrating feeder. The objects to be sorted enter the vibrating feeder's receiving plate through the feed inlet of the chute-type sorting device. The vibrating feeder then vibrates, guiding the objects to be sorted to the material drop area for unsupported falling motion.

[0080] Next, at step S420, the falling object to be sorted is scanned at a scanning area along the unsupported falling trajectory. In one implementation scenario, the scanning area is scanned by an X-ray identification device. The X-ray identification device may include an X-ray transmitter and multiple X-ray receivers. The X-ray transmitter and X-ray receivers are respectively positioned on opposite sides of the falling trajectory of the object.

[0081] Next, at step S430, based on the aforementioned scan, the blocks to be separated from the blocks to be sorted are identified, and the separation mechanism to be used to separate the blocks is determined. In the disclosed embodiment, the separation mechanism includes at least two levels of separation mechanisms, arranged at different heights below the scanning area and along the falling trajectory of the blocks. Each level of separation mechanism is suitable for processing different particle size ranges. Therefore, the separation mechanism to be used can be determined based on different conditions.

[0082] In some embodiments, determining the separation mechanism to be used to separate the blocks to be separated may include determining a suitable separation mechanism based on the particle size of the blocks to be separated, as the previously determined separation mechanism. For example, based on the particle size of the blocks to be separated, a separation mechanism corresponding to the processing particle size range within which the blocks to be separated fall may be selected. In this manner, more precise separation can be achieved, avoiding the use of an inappropriate separation mechanism for separation, thereby improving separation accuracy.

[0083] Furthermore, in some embodiments, determining the separation actuator that will perform separation on the object to be separated may further include: determining whether the separation operation can be performed when the object to be separated falls to its suitable separation actuator; and in response to determining that the separation operation cannot be performed when the object to be separated falls to its suitable separation actuator, using the next-level separation actuator of its suitable separation actuator as the aforementioned determined separation actuator. By using this method of supplementing the operation of the next-level separation actuator, it is possible to avoid the situation where the data has not been processed when the object reaches its suitable separation actuator due to the large amount of recognition calculation and high load of the control mechanism, thereby missing separation. Although the next-level separation actuator may not be suitable for the object to be separated, it can improve the overall efficiency of the equipment.

[0084] In some embodiments, determining whether a separation operation can be performed when the object to be separated falls to its suitable separation actuator may include: determining whether the time difference between the time when the suitable separation actuator receives the information of the object to be separated and the start time of scanning the object to be separated is greater than a predetermined time difference Δt', wherein the predetermined time difference Δt' is the falling time of the object to be separated from the scanning area to its suitable separation actuator; and if the above time difference is greater than the predetermined time difference Δt', determining that the separation operation cannot be performed when the object to be separated falls to its suitable separation actuator.

[0085] In other embodiments, determining whether the separation operation can be performed when the object to be separated falls to its suitable separation actuator may include: determining whether the difference between the time when the object to be separated reaches its suitable separation actuator and the current time exceeds a set threshold, where the current time is the time when the object to be separated is processed, and the set threshold can be determined based on the indicated transmission time and the response time of the separation actuator; and if the set threshold is exceeded, determining that the separation operation cannot be performed when the object to be separated falls to its suitable separation actuator.

[0086] Finally, at step S440, the determined separation actuator is instructed to separate the object to be separated. The separation actuators can be of the same or different types, including but not limited to a blowing mechanism and a push plate mechanism. Depending on the different separation actuators, the control mechanism may also indicate corresponding separation execution parameters. For example, for a blowing mechanism, the control mechanism may determine a gas injection coefficient based on the physical information of the object to be separated, where the gas injection coefficient indicates the force of the gas injection control; and send a gas injection separation instruction and the gas injection coefficient to the blowing mechanism. Specifically, a ratio can be calculated based on the weight and particle size of the object to be separated, and this ratio corresponds to a preset gas injection coefficient. The gas injection coefficient is generally between 0.5 and 1.5. It will be understood that the larger the ratio, the larger the gas injection coefficient, and the greater the force of the gas injection control. For another example, for a push plate mechanism, the control mechanism may determine one or more push plates to perform separation based on the center of mass position information of the object to be separated and the width of the object; and send a push plate separation instruction to the driver of the determined one or more push plates.

[0087] Taking into account that the particle size range of the objects to be sorted may change dynamically, in order to better adapt to different particle size ranges, some embodiments of the present disclosure also provide an adjustable object sorting system. Specifically, based on the object sorting system of Figure 2, a height adjustment mechanism is added to adjust the height of at least one level of separation actuator to match the changing particle size range. The height adjustment mechanism can be implemented in various ways, and only a few exemplary implementations are provided below to help better understand the present application. However, those skilled in the art can make various modifications and changes based on the teachings of the present application, which all fall within the spirit of the present application.

[0088] Considering that the lower limit of the particle size of the objects processed generally does not vary much, while the upper limit varies greatly, in some embodiments, the separation actuator for processing smaller particle sizes can be fixed, while the separation actuator for processing larger particle sizes can be height-adjustable. Specifically, a lifting mechanism can be installed on the lowest separation actuator to adjust the height of the lowest separation actuator.

[0089] FIG5 illustrates a block sorting system according to some embodiments of the present disclosure.

[0090] As shown in the figure, similar to Figure 2, the block sorting system 500 includes a feeding mechanism 21, a detection mechanism 22, a control mechanism (not shown) and a separation actuator 24. In this example, the separation actuator 24 includes two-stage separation actuators 241 and 242. The first-stage separation actuator 241 is suitable for processing blocks of smaller particle size, and its vertical distance relative to the detection mechanism 22 is closer, that is, its height is higher. The second-stage separation actuator 242 is suitable for processing blocks of larger particle size, and its vertical distance relative to the detection mechanism is farther, that is, its height is lower. In this embodiment, the height of the first-stage separation actuator 241 is fixed, and a lifting mechanism 51 is installed below the second-stage separation actuator 242 for adjusting the height of the second-stage separation actuator 242, so as to adapt to different particle size ranges and increase the flexibility of the block sorting equipment.

[0091] In some embodiments, the lifting mechanism 51 may be an electric push rod or a pneumatic cylinder. Those skilled in the art will appreciate that the specific type of lifting mechanism required may be adjusted and configured by those skilled in the art based on actual needs and experience, and the disclosed embodiments are not limited in this respect.

[0092] In other embodiments, a height adjustment device may be provided for each level of separation actuator, thereby adapting to the particle size range of the objects in a wider and more flexible manner.

[0093] FIG6 schematically illustrates a height adjustment mechanism. As shown, the height adjustment mechanism 600 includes a mounting bracket 610 and a plurality of horizontal support plates 620. The horizontal support plates 620 are mounted on the mounting bracket 610 and are used to place or mount the separation actuator. The horizontal support plates can have various configurations for securing the separation actuator, and the disclosed embodiments are not limited in this respect. The height of the horizontal support plates on the mounting bracket is adjustable. By adjusting the height of the horizontal support plates, the height of the separation actuator placed thereon can be adjusted.

[0094] There are many ways to implement the height adjustment of the horizontal support plate. In some implementations, the mounting bracket 610 may include at least one pair of longitudinal slide rails 630 for at least one horizontal support plate to slide longitudinally along the mounting bracket, thereby adjusting the height of the at least one horizontal support plate on the mounting bracket. This type of slide rail can facilitate continuous height adjustment to accurately match the height setting requirements. It should be understood that the slide rails in the figure are only schematically shown, and those skilled in the art can adopt various currently available slide rail structures to implement as needed. In other implementations, the mounting bracket 610 may include a plurality of groups of mounting positions (not shown) spaced apart in its longitudinal direction for optional installation of horizontal support plates, thereby adjusting the height of the horizontal support plates. The mounting position can be implemented in various forms, including but not limited to jacks, protrusions, etc.

[0095] In some embodiments, the separation force of the separation actuator is adjustable. The separation force refers to the intensity of the separation action. Depending on the different separation actuators, the separation force can be controlled by different separation execution parameters. For example, for the blowing mechanism, the force of controlling the air jet can be indicated by the air jet coefficient. Specifically, a ratio can be calculated based on the weight of the object and the particle size, and this ratio corresponds to the preset air jet coefficient. It can be understood that the larger the ratio, the larger the air jet coefficient, and the greater the force of controlling the air jet. For another example, for the push plate mechanism, the force of controlling the push can be indicated by the number of push plates. Specifically, based on the center of mass position information of the object to be separated and the width of the object, the number of push plates for performing the separation is determined. By adjusting the separation force, the particle size range of the object that the separation actuator is suitable for processing can be adjusted. This way of adjusting the separation force avoids the inconvenience of replacing the separation actuator when a new particle size range needs to be matched.

[0096] By providing such a block sorting device with a height adjustment mechanism, it is possible to set the heights of the separation actuators at each level according to the height setting principle described above for a specific processing particle size range, and then adjust the corresponding separation actuators to the corresponding heights, thereby achieving a wide particle size range and accurate sorting.

[0097] Although a plurality of embodiments of the present disclosure have been shown and described herein, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Those skilled in the art may conceive of many modifications, changes, and alternatives without departing from the ideas and spirit of the present disclosure. It should be understood that in practicing the present disclosure, various alternatives to the embodiments of the present disclosure described herein may be adopted. The appended claims are intended to define the scope of protection of the present disclosure and therefore cover equivalents or alternatives within the scope of these claims.

Claims

1. A method for sorting blocks, characterized in that: The method comprises: Guide the blocks to be sorted to the material drop point for unsupported falling motion; Scanning the block to be sorted at a scanning area on the falling trajectory of the unsupported falling motion; Based on the scanning, identifying the blocks to be separated among the blocks to be sorted, and determining a separation execution mechanism for performing separation on the blocks to be separated; and Instructing the determined separation execution mechanism to perform separation on the to-be-separated object blocks; The separation execution mechanism comprises at least two levels of separation execution mechanisms arranged on the falling track and at different heights below the scanning area, and each level of separation execution mechanism corresponds to a different processing particle size range.

2. The object sorting method according to claim 1, wherein the determining of the separation execution mechanism to be used to separate the object to be separated comprises: Based on the particle size of the object to be separated, a separation execution mechanism suitable for the object to be separated is determined as the determined separation execution mechanism.

3. The object sorting method according to claim 2, wherein the determining of the separation execution mechanism to perform separation on the object to be separated further comprises: Determining whether a separation operation can be performed when the object to be separated falls to the suitable separation execution mechanism; as well as In the case where the separation operation cannot be performed when the object to be separated falls to the suitable separation execution mechanism, a next-level separation execution mechanism of the suitable separation execution mechanism is used as the determined separation execution mechanism.

4. The object sorting method according to claim 3, wherein the step of determining whether the separation operation can be performed when the object to be separated falls to the suitable separation execution mechanism comprises: Determine whether the time difference between the time when the suitable separation execution mechanism receives the information of the object block to be separated and the time when the scanning of the object block to be separated starts is greater than a predetermined time difference Δt', wherein the predetermined time difference Δt' is the falling time of the object block to be separated from the scanning area to the suitable separation execution mechanism; as well as If the time difference is greater than the predetermined time difference Δt′, it is determined that the separation operation cannot be performed when the object to be separated falls to the suitable separation execution mechanism.

5. The object sorting method according to claim 3, wherein the determining whether the separation operation can be performed when the object to be separated falls to the suitable separation execution mechanism comprises: Determine whether the difference between the time when the object to be separated reaches its suitable separation actuator and the current time exceeds a set threshold, wherein the current time is the time when the current object to be separated is processed, and the set threshold is determined according to the transmission time of the indication and the response time of the separation actuator; as well as If the set threshold is exceeded, it is determined that the separation operation cannot be performed when the object to be separated falls to the suitable separation execution mechanism.

6. The block sorting method according to claim 1, wherein the at least two levels of separation actuators are arranged from high to low on the falling trajectory in the order of processed particle sizes from small to large.

7. The block sorting method according to claim 6, wherein the vertical distance between each level of separation actuator and the point where the material falls is determined according to the upper limit of the particle size range it processes, and the larger the upper limit of the particle size, the longer the vertical distance.

8. The block sorting method according to any one of claims 1 to 7, wherein the at least two-stage separation actuator is selected from any one of the following or a combination thereof: a blowing mechanism or a push plate mechanism.

9. A block sorting system, characterized in that: include: A feeding mechanism, a detection mechanism, a control mechanism and at least two-stage separation actuators, wherein: The feeding mechanism is used to guide the blocks to be sorted to the material drop location for unsupported falling transportation. move; The detection mechanism is arranged on the falling track of the unsupported falling motion, and is used to scan the block to be sorted; The control mechanism is used to identify the to-be-separated blocks among the to-be-sorted blocks based on the scanning of the detection mechanism, determine a separation execution mechanism for performing separation on the to-be-separated blocks, and issue an instruction to the determined separation execution mechanism; and The at least two levels of separation actuators are arranged on the falling track and at different heights below the detection mechanism. Each level of separation actuator is suitable for a different processing particle size range and is used to separate the blocks to be separated according to the instructions of the control mechanism.

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