CN111282827B - Automatic workpiece feeding and quick sorting control method - Google Patents
Automatic workpiece feeding and quick sorting control method Download PDFInfo
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- CN111282827B CN111282827B CN202010129365.XA CN202010129365A CN111282827B CN 111282827 B CN111282827 B CN 111282827B CN 202010129365 A CN202010129365 A CN 202010129365A CN 111282827 B CN111282827 B CN 111282827B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C1/00—Measures preceding sorting according to destination
- B07C1/02—Forming articles into a stream; Arranging articles in a stream, e.g. spacing, orientating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C3/00—Sorting according to destination
- B07C3/10—Apparatus characterised by the means used for detection ofthe destination
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Abstract
The invention relates to an automatic loading quick sorting control method, which is characterized in that an automatic separation process is arranged at the front end of loading goods into a sorting machine, a manual piece-by-piece loading mode is cancelled, and a mechanical separation device and a circulating piece waiting mode are adopted, so that the operation pressure of piece-by-piece loading after unpacking is solved, the piece-by-piece scanning identification and piece loading speed and accuracy are improved, the manual quantity of piece loading and the load of workers are effectively reduced, and the high-speed operation and sorting efficiency of the sorting machine are fundamentally ensured. The method comprises the following steps: 1) unpacking the goods, namely splitting the goods conveyed from the first conveying line into small goods in an unpacking unit; 2) separating, conveying the unpacked small piece cargos to a separating unit and separating the small piece cargos into a flat state on a conveying line; 3) scanning, namely scanning codes through a 3d +2d vision unit, inputting the outline dimension data of each cargo, and establishing a subsequent sorting task through the generated coordinate information; 4) loading, transferring the goods to a sorting machine guiding unit by a mechanical arm grabbing unit; 5) sorting, the goods enter the conveying line of the sorting machine through the sorting machine guide-in unit until the sorting task is completed.
Description
Technical Field
The invention relates to an automatic loading control method for implementing high-speed cargo sorting, belonging to the field of logistics sorting.
Background
The logistics sorting operation site of the existing e-commerce and express delivery industries usually adopts an operation mode of manually loading pieces at the front end, so that a large number of unpacked goods are manually separated from each other and enter a conveying line in a pile, and subsequent scanning and information input are facilitated.
The manual workpiece supply mode at the front end of the existing high-speed sorting machine needs to be configured with a plurality of workers. Sorting equipment is usually operated at higher speeds and cannot be shut down, with correspondingly higher requirements on the quality of the personnel who manually load the pieces and greater field labor intensity. If the phenomenon that the processing speed of the goods is reduced appears in the period, a large amount of piled goods still enter a subsequent scanning and sorting stage, so that a large amount of goods is overstocked, the scanning and sorting operation pressure is increased, and a large amount of unidentified goods enter the goods loading and scanning procedures again, so that the processing efficiency of the whole sorting operation is directly influenced, the working time of the whole equipment is prolonged, and the sorting efficiency and the sorting capacity of a logistics system are reduced.
In view of this, the present patent application is specifically proposed.
Disclosure of Invention
The invention relates to an automatic workpiece feeding quick sorting control method, which aims to solve the problems in the prior art, an automatic separation process is arranged at the front end of a workpiece fed into a sorting machine, a manual workpiece feeding mode is cancelled, and a mechanical separation device and a circulating workpiece waiting mode are adopted, so that the operation pressure of the unpacked workpiece fed one by one is solved, the speed and the accuracy of the workpiece feeding scanning identification and the workpiece feeding are improved, the manual workpiece feeding quantity and the load of workers are effectively reduced, and the high-speed operation and the sorting efficiency of the sorting machine are fundamentally ensured.
In order to achieve the design purpose, the automatic loading and quick sorting control method comprises the following implementation steps:
1) unpacking goods
The goods conveyed from the first conveying line are split into small goods in the unpacking unit;
2) separation of
Conveying the unpacked small goods in piles to a separation unit and separating the small goods into flat state on a conveying line;
3) scanning
Scanning codes through a 3d +2d vision unit, inputting the overall dimension data of each cargo, and establishing a subsequent sorting task through the generated coordinate information;
if the code scanning fails, the subsequent loading step is not influenced;
4) upper piece
Transferring the goods to a sorting machine guide-in unit by a manipulator grabbing unit;
in the step, the goods which fail to scan the code before are replenished with the code by the bottom scanning unit;
5) sorting
The goods enter the conveying line of the sorting machine through the sorting machine guide-in unit until the sorting task is completed.
In the control flow for realizing the method, an unpacking unit, a 3d +2d vision unit, a sorting machine guide-in unit and a sorting machine are arranged along the conveying direction, a separation unit is arranged between the unpacking unit and the 3d +2d vision unit, and a manipulator grabbing unit and a bottom scanning unit are sequentially connected between the 3d +2d vision unit and the sorting machine guide-in unit.
The 3D +2D vision unit comprises a 3D camera, a 2D camera, a scanning unit and a vision controller. The 3d +2d vision unit generates real-time position and outline dimension information of the goods through the photographing device, so that length, width and height dimension data of the goods can be acquired. Meanwhile, the bar code information of the goods is directly input through the scanning unit, and the goods are transferred to the sorting machine guiding unit through the mechanical arm grabbing unit.
After manual or automatic unpacking unit is adopted for unpacking, the piled cargos entering the separation unit can be separated into a flat state on the conveying line before scanning and loading, so that the execution rate of subsequent scanning and loading operation is high, a large amount of operators are not required, and the whole sorting efficiency and the operation capacity are improved. Moreover, in the process that the manipulator snatchs unit and goes up the piece, can fail to sweep the goods of sign indicating number discernment to front end 3d +2d visual cell, carry out supplementary scanning through bottom scanning unit, can improve the flow of once going up and sweep the rate of accuracy that sign indicating number discernment, bind with the letter sorting task, help improving whole letter sorting efficiency.
In order to further improve the preliminary separation efficiency and increase the goods spacing in a flat state after separation. In the separation step, the piled goods are separated into a flat state by the speed difference and the height difference between the conveying lines of the separation unit. The stacked cargoes are separated to the maximum extent and the distance is increased through the speed difference and the height difference.
Further, in order to improve the separated piece feeding efficiency, the unpacked goods in a flat state are circularly conveyed on the annular conveying line until being grabbed by the mechanical hand grabbing unit and enter the subsequent piece feeding step. That is, if the unpacked goods in the flat state cannot be grabbed at one time, the goods can be circularly conveyed on the annular conveying line until being grabbed again by the mechanical arm grabbing unit.
In summary, the automatic workpiece feeding and rapid sorting control method has the advantages and beneficial effects that:
1. the full-link full-automatic operation requirement that a large amount of unpacked goods automatically enter the high-speed sorting machine is met, and the original manual loading link is replaced.
2. The labor investment can be greatly reduced, the operation intensity and the operation amount of workers are reduced, and the requirement on the quality of the workers is lowered.
3. The sorting efficiency of the whole machine is improved, and the sorting accuracy and the sorting capacity are improved integrally.
4. The existing traditional sorting scheme is improved, and the full automation degree of sorting equipment is promoted.
Drawings
The invention will now be further described with reference to the following figures.
FIG. 1 is a schematic flow chart of an automatic workpiece loading and rapid sorting control method according to the present application;
FIG. 2 is a schematic diagram of an automatic part loading device for implementing the rapid sorting control method of the present application;
FIG. 3 is a schematic view of the structure of the separation unit of FIG. 2;
FIG. 4 is a schematic view of the camera coordinate setting;
FIG. 5 is a schematic diagram of the camera detection boundary setting;
FIG. 6 is a schematic view of a robot grasping judgment;
FIG. 7 is a schematic view illustrating the determination of entering a capture area;
in the above figures, the first conveyor line 1, the unpacking unit 2, the unpacking chute 3, the endless conveyor line 4, the separating unit 5, the 3d +2d vision unit 6, the manipulator grabbing unit 7, the bottom scanning unit 8, the sorter introduction unit 9, the sorter 10, the conveyor belt 11, the motor assembly 12, and the frame 13.
Detailed Description
Embodiment 1, as shown in fig. 1 and 2, the automatic loading and fast sorting control method according to the present application employs an automatic loading device, which includes a first conveying line 1, an unpacking unit 2, an unpacking chute 3, a separating unit 5, a 3d +2d vision unit 6, a manipulator grabbing unit 7, a bottom scanning unit 8, a sorting machine introduction unit 9, and a sorting machine 10, which are sequentially arranged along a conveying direction.
Wherein a separation unit 5 is arranged between the unpacking unit 2 and the 3d +2d vision unit 6;
a manipulator grabbing unit 7 and a bottom scanning unit 8 are sequentially connected between the 3d +2d vision unit 6 and the sorting machine guide-in unit 9;
an annular conveying line 4 is arranged between the unpacking unit 2 and the bottom scanning unit 8, and the separating unit 5 forms a part of the annular conveying line 4;
a 3d +2d vision unit 6 and a robot gripping unit 7 are provided on the endless conveyor line 4.
The separation unit 5 comprises 4 sections of conveying belts 11 arranged on a rack 13, and each section of conveying belt 11 is driven by a motor assembly 12; the linear speed and the vertical fall of each conveyor belt 11 are gradually increased along the conveying direction.
The automatic loading quick sorting control method comprises the following implementation steps:
1) unpacking goods
The cargo conveyed from the first conveyor line 1 is separated into small pieces of cargo by the unpacking unit 2;
2) separation of
Conveying the unpacked small piled cargos to a separation unit 5, separating the small piled cargos into a flat state through a plurality of groups of speed differences and height differences among the sequentially connected conveying lines, and circularly conveying the cargos in the flat state on an annular conveying line 4 until the cargos are grabbed by a manipulator grabbing unit 7 to enter the subsequent loading step;
3) scanning
Scanning codes through the 3d +2d vision unit 6, inputting the overall dimension data of each cargo, and establishing a subsequent sorting task through the generated coordinate information; if the code scanning fails, the subsequent loading step is not influenced;
4) upper piece
The goods are transferred to a sorter introduction unit 9 by the manipulator grabbing unit 7; in this step, for the goods that failed to scan the code before, the code scanning is supplemented again by the bottom scanning unit 8;
5) sorting
The goods are fed through the sorter infeed unit 9 into the conveyor line of the sorter 10 until the sorting task is completed.
According to the automatic quick sorting control process for the fed goods, the goods are manually/automatically unpacked and then enter the separation unit in a pile to be separated to become a flat state, then are scanned, identified and information recorded, and then are transferred to the sorting machine to finish final leading-in and feeding of the goods through the mechanical arm grabbing unit, the whole process only needs a small amount of unpacking personnel to operate, and the operation efficiency of the whole sorting system is high.
In the step 4) of loading, after the goods in a tiled state are scanned by a 3d +2d vision unit, coordinate position information and overall dimension data of the goods are obtained, a vision system selects and picks a grabbed object through algorithm processing, and pre-path planning and grabbing sequence judgment are implemented by comparing the overall dimension information of the goods with a path possibly formed after the mechanical arm grabs the goods.
Through the judgment of the path planning and the grabbing sequence in advance, whether the space interference exists or not needs to be judged according to the cargo height data. That is, when the path of the manipulator grabbing the goods is planned, whether the moving height of the manipulator grabbing the goods is smaller than or equal to the height coordinate of the adjacent goods or not is judged, when the grabbing motion is executed, the adjacent goods and the moving path of the manipulator generate spatial interference, namely, the manipulator can collide with the adjacent goods when grabbing the goods, and the grabbing path is abandoned. On the contrary, if the grabbing path is judged not to generate spatial interference, the grabbing path is feasible and can be used as one of the alternative paths for subsequent grabbing sequence judgment.
Based on the 3d +2d vision unit 6, the items to be judged before the manipulator grabbing unit 7 performs the action of grabbing the goods include that the dynamic path planning and the grabbing sequence judgment are uniformly performed according to the current coordinate position and the external dimension information of the goods, such as the length, width, height and size data of the goods, the space position information, the grabbing sequence of a plurality of goods to be grabbed, the advancing path for grabbing each goods, and the like.
According to the bar code information obtained by scanning the code, the elements of different goods types, manufacturer information, goods receiving and dispatching addresses and the like are gathered and form a sorting task, and the goods are distributed to different specified target areas according to different sorting conditions.
After the goods pass through the 3d +2d camera, the length, width and height of each goods and the coordinate information of the goods on the conveying line can be read by the visual controller, and the position of the 3d +2d camera is fixed, so that the coordinate information read by the visual controller at the moment of photographing of each goods is determined and unique; and, the transfer chain moves with the speed of invariant, therefore the goods coordinate position when entering the manipulator and snatching the scope all can be confirmed, and the manipulator can judge the goods that get into the field of vision this moment, and under the prerequisite that confirms that the path of snatching of waiting to snatch the goods can not take place to interfere with other goods, the manipulator can preferentially snatch the first goods that get into and snatch the scope.
In the step 4), the following path planning and grabbing sequence judging process is executed:
1. visual inspection boundary division and coordinate setting of camera
As shown in fig. 4, after the 2d camera is fixed, coordinates and a detection boundary need to be set on the conveying line, and a point O is arbitrarily selected on the conveying line as a zero point coordinate; selecting positive directions of an X axis and a Y axis, measuring data from a coordinate origin O of the separation conveying line to edges X1, X2, Y1 and Y2 of the conveying line, and inputting the measured data into a visual control algorithm to obtain a visual detection boundary as shown in FIG. 5;
the length, width and height data of the goods are measured by the vision controller through the 3d camera, namely after the goods enter the vision detection boundary, the physical boundary of the goods is generated to obtain the peripheral dimension and coordinate information.
2. Mechanical arm coordinate grabbing area division and position information binding
As shown in fig. 6, O1 is the center point of the fixed position of the manipulator, O2 is the initial zero position of the chuck of the manipulator performing the grabbing action, and assuming that the coordinates of O1 are (xo1, yo1), the coordinates of O2 are (xo2, yo2, zo2), the coordinates of O1 are measured based on the actual fixed positions of the manipulator and the camera, the distances a1 and b1 between the O1 point and the 2d selected coordinate origin O of the camera along the positive X-axis and the positive Y-axis are measured by the distance measuring tool, the coordinates corresponding to the O1 point are (a1, b1), and the distances a1 and b1 along the positive X-axis and the positive Y-axis of the chosen coordinate origin O of the manipulator at the zero-point of the manipulator are measured by the distance measuring tool, and the height z 1 between the O1 point and the plane of the distance measuring tool transfer line O1 point is measured at the same time, then the actual coordinates of the O1 point of the manipulator 1 can be determined as (a1+ a1, 1+ a1 b1 coordinate of the manipulator for determining the basic goods grabbing time of the manipulator; meanwhile, a transmission coordinate system is established through an encoder on the conveying line, and the manipulator comprehensively judges the grabbing sequence according to the information of the conveying line running speed V1, the manipulator grabbing speed V2, the grabbing path length L and the like.
3. Selection and path planning of manipulator grabbing object
At the same time, a plurality of objects which can be grabbed may exist in the grabbing range, and at the moment, the vision controller can judge whether space interference exists in the preferable grabbing object, namely the first goods entering the grabbing range. If not, executing a grabbing action; if yes, abandoning the grabbing action; and then whether the space interference exists in the second goods entering the grabbing range is judged in sequence, and the rest can be done in the same way.
The manipulator can be arranged on the conveying line to progressively execute path planning and grabbing judgment, the goods abandoned to be grabbed by the current manipulator can be transferred to the next manipulator grabbing station along with the conveying line, grabbing judgment and path planning are executed according to the same principle and algorithm, and the multiple manipulators can cooperatively work to finish the loading task of the goods. Specifically comprises the following steps
3.1 determination of whether cargo enters the gripping area
As shown in fig. 7, the dotted filling area represents the maximum area that can be grasped by the robot, and the time required for the robot to move from the origin state to the outermost peripheral boundary of the grasping area is t1(t1 is determined according to the robot parameter setting);
there are two cases for whether the goods can be grabbed:
in the first case, as shown in fig. 6, the cargo 1 is already in the gripping area of the robot when the robot is in the home position, and if the cargo 1 is moved to the next position 1 'at the conveyor line moving speed V after the time t1, the algorithm considers the cargo 1 to be in the gripping area if the center coordinates of 1' are still in the gripping area of the robot. Otherwise, the algorithm determines that the cargo 1 is not in the pick-up area.
In the second case, as shown in fig. 6, when the robot is in the home position, the cargo 3 is outside the robot gripping area, and if the time t1 has elapsed, the cargo 3 moves to the next position 3 'at the conveyor line moving speed V, and if the 3' center coordinate is inside the robot gripping area, the algorithm considers the cargo 3 to be in the gripping area. Otherwise, the algorithm determines that the cargo 3 is not in the pick-up area.
3.2 manipulator grabbing path planning
As shown in fig. 6, the manipulator grasping area is an area centered on a manipulator fixing position center point O1, and the maximum distance in the camera shooting plane direction in the mechanical limit state where the manipulator can extend is a radius; for the selection of the manipulator to grab the goods, whether the goods enter the grabbing area is judged as described above. After the grabbed object is determined, the manipulator plans the grabbing path.
Suppose there are 4 goods that can be grabbed simultaneously in the manipulator grabbing area, 1 ', 2', 3 ', 4' are the real-time positions of the manipulator grabbing time, respectively.
The visual controller obtains the height information of the goods and the coordinate information obtained by algorithm processing, and firstly, the final grabbing coordinate of the goods and the pressing height of the sucking disc are calculated. Secondly, the manipulator plans a cargo grabbing and goods placing path according to a pre-judged priority according to a straight path, if cargo exists in the grabbing path, the height information of the object on the grabbing path is judged, and if the adjacent cargo on the grabbing path is judged not to interfere in space, the manipulator determines the shortest path for grabbing the current cargo; if the grabbing path is judged to be spatially interfered with the adjacent goods, the algorithm avoids selecting the curve path when planning the grabbing and putting paths of the current goods.
3.3 grab selection when multiple goods can be grabbed
When a plurality of goods which can be grabbed exist in the grabbing area of the manipulator, the grabbing paths of the goods are compared by the algorithm, and the goods with the shortest grabbing path is found out to be the grabbing object. As shown in step 3.2, 4 goods capable of being grabbed simultaneously exist in the manipulator grabbing area, the lengths of the corresponding grabbing paths are L1, L2, L3 and L4, and L1 is smaller than any one of L2, L3 and L4, then the grabbing path corresponding to the goods 1 'is determined to be the optimal path, at this time, the manipulator will select to grab the goods 1', and similarly, when other goods wait for the manipulator to return to the origin after the manipulator performs the grabbing and placing actions, the algorithm determination is continued to search for the optimal grabbing path.
In order to improve the grabbing efficiency, a plurality of mechanical arms simultaneously work in a coordinated mode on one conveying belt, for goods which are missed by the preorder mechanical arms, the follow-up mechanical arms can grab and put the goods according to the same grabbing strategy, in order to improve the grabbing efficiency and the success rate to the maximum extent, the parameters of the mechanical arms need to be set, and grabbing and putting tasks are better achieved by changing the grabbing beat and the pressing height.
4. Parameter setting of grabbing sucker of manipulator
The manipulator snatchs the mode that the goods adopted the sucking disc to absorb the goods, and to the goods of different grade type, the pressure parameter that the sucking disc pushed down is adjustable to improve the pressure adjustment of snatching to the goods, improve on the quick discernment basis of accomplishing the goods target and snatch stability, avoid the emergence of goods phenomenon that drops.
In summary, the embodiments presented in connection with the figures are only preferred. Those skilled in the art can derive other alternative structures according to the design concept of the present invention, and the alternative structures should also fall within the scope of the solution of the present invention.
Claims (2)
1. An automatic loading and quick sorting control method is characterized in that: comprises the following implementation steps of the method,
1) unpacking goods
The goods conveyed from the first conveying line (1) are split into small goods in the unpacking unit (2);
2) separation of
Conveying the unpacked small goods in piles to a separation unit (5) and separating the small goods in a flat state on a conveying line;
circularly conveying the unpacked goods in a flat state on an annular conveying line (4) until the goods are grabbed by a manipulator grabbing unit (7) and enter the subsequent loading step;
3) scanning
Scanning codes through a 3d +2d vision unit (6), inputting the overall dimension data of each cargo, and establishing a subsequent sorting task through the generated coordinate information;
if the code scanning fails, the subsequent loading step is not influenced;
4) upper piece
Transferring the goods to a sorting machine introduction unit (9) by a manipulator grabbing unit (7);
in the step, the goods which fail to scan the code before are replenished with the code scanning by the bottom scanning unit (8);
the visual system selects and picks the grabbed objects through algorithm processing, compares the goods outline size information with a path possibly formed after the mechanical arm grabs to implement path planning in advance and grabbing sequence judgment, and judges whether the space interferes or not according to the goods height data;
the path planning and grasping sequence judgment comprises the following procedures,
4.1) visual inspection boundary division and coordinate setting of Camera
Setting coordinates and a detection boundary on a conveying line, measuring length, width and height data of the goods by a visual controller through a 3d camera, and generating a physical boundary of the goods after the goods enter the visual detection boundary to obtain peripheral dimension and coordinate information;
4.2) division of manipulator coordinate grabbing area and binding of position information
4.3) selection and Path planning of the robot grasping the object
At the same time, a plurality of objects which can be grabbed exist in the grabbing range, and the vision controller judges whether space interference exists in the preferred object to be grabbed, namely the first goods entering the grabbing range; if not, executing a grabbing action; if yes, abandoning the grabbing action; then, whether space interference exists in the second goods entering the grabbing range or not is judged in sequence, and the rest is done in the same way;
the method comprises the following steps that a plurality of mechanical hands are arranged on a conveying line to progressively execute path planning and grabbing judgment, for goods abandoned to be grabbed by the current mechanical hand, the goods are transported to a next mechanical hand grabbing station along the conveying line, grabbing judgment and path planning are executed according to the same principle and algorithm, and a plurality of mechanical hands cooperate to complete a goods loading task;
4.3.1) determination of whether goods enter the gripping area
4.3.2) manipulator grabbing path planning
The manipulator grabbing area is an area which takes a central point of a manipulator fixing position as a center and takes the maximum distance in the camera shooting plane direction as a radius in the mechanical limit state that the manipulator can extend out; for the selection of the manipulator to grab the goods, judging whether the goods enter the grabbing area or not; after the grabbed object is determined, the manipulator plans a grabbing path;
the visual controller obtains height information of the goods and coordinate information obtained by algorithm processing, and firstly, the final grabbing coordinate of the goods and the pressing height of the sucking disc are calculated; secondly, the manipulator plans a goods grabbing and putting path according to a pre-judged priority according to a straight path, and if goods exist in the grabbing path, the height information of the objects on the grabbing path is judged; if the adjacent goods on the grabbing path are judged not to interfere in space, the manipulator determines the shortest path for grabbing the current goods; if the grabbing path is judged to be spatially interfered with the adjacent goods, the algorithm avoids selecting a curve path when planning the grabbing and putting paths of the current goods;
4.3.3) grab options when multiple goods can be grabbed
When a plurality of goods which can be grabbed exist in the grabbing area of the manipulator, the grabbing paths of the goods are compared, and the goods with the shortest grabbing path is found out to be a grabbing object;
4.4) setting of parameters of grabbing sucker of manipulator
The manipulator grabs the goods by adopting a mode of sucking the goods by the sucking disc, and for different types of goods, the pressure parameter of the downward pressing of the sucking disc is adjustable, so that the grabbing pressure adjustment for the goods is improved;
5) sorting
The goods enter a conveying line of the sorting machine (10) through a sorting machine guide-in unit (9) until a sorting task is completed.
2. The automatic loading quick sorting control method according to claim 1, wherein: in the separation step, the piled goods are separated into a flat state through the speed difference and the height difference between the conveying lines of the separation unit (5).
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| CN114377969B (en) * | 2021-12-28 | 2024-06-14 | 科捷智能科技股份有限公司 | Automatic feeding sorting control method |
| CN114092020B (en) * | 2022-01-20 | 2022-08-19 | 诚天国际供应链(深圳)有限公司 | Control system and integrated warehousing device based on control system |
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