CN112793982B - Stacker goods taking and placing system and application method thereof - Google Patents
Stacker goods taking and placing system and application method thereof Download PDFInfo
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- CN112793982B CN112793982B CN202110317105.XA CN202110317105A CN112793982B CN 112793982 B CN112793982 B CN 112793982B CN 202110317105 A CN202110317105 A CN 202110317105A CN 112793982 B CN112793982 B CN 112793982B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
- B65G1/02—Storage devices
- B65G1/04—Storage devices mechanical
- B65G1/0407—Storage devices mechanical using stacker cranes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G1/00—Storing articles, individually or in orderly arrangement, in warehouses or magazines
- B65G1/02—Storage devices
- B65G1/04—Storage devices mechanical
- B65G1/137—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed
- B65G1/1373—Storage devices mechanical with arrangements or automatic control means for selecting which articles are to be removed for fulfilling orders in warehouses
Abstract
A stacker pick-and-place system and an application method thereof comprise an upper computer, a stacker, goods, a tray, a goods shelf and a PLC control unit; the upper computer sends the goods outline dimension data to the stacker; the stacking machine receives the goods outline dimension data sent by the upper computer and executes a goods picking and placing program; a cargo shape detection system based on visual camera ranging is installed on the cargo carrying platform; placing the goods on the tray; the goods shelf is used for storing goods and comprises a fixed goods shelf or a telescopic goods shelf; the PLC control unit is arranged on the cargo carrying platform and is used for system control and output alarm; the application method of the system comprises four steps: scheduling tasks of the upper computer; scanning goods shape data and detecting the shape of the goods when the goods enter a goods carrying table; detecting the appearance of the goods in the target goods space in an overrun way; and (5) processing the problem of the appearance overrun of the goods. The invention can effectively solve the problem that the appearance of the flexible storage goods of the stereoscopic warehouse exceeds the limit.
Description
Technical Field
The invention relates to the field of logistics storage automation, in particular to a stacker goods taking and placing system and an application method of the system.
Background
The goods taking action flow of the stacker is as follows: the stacker is positioned to the position of the taken tray, and the cargo carrying platform is at a low position at the moment, so that the fork can conveniently extend into a cargo groove under the bottom of the tray, and then the fork extends into the cargo groove of the corresponding tray and is positioned right below the tray; then the goods carrying platform is lifted, the goods can be picked up by the fork and separated from the goods shelf, and finally the fork retracts to bring the goods back to the goods carrying platform.
The stacker cargo handling action flow is as follows: the stacker is full-load to be fixed a position to putting the tray, and the stacker carries the cargo bed to be in the high position this moment, and then the fork takes the goods to stretch out, and the platform of carrying the cargo this moment is in the high position, and the goods is directly over goods shelves, later carries the cargo bed to drop to the low level, and the goods falls on goods shelves and breaks away from the fork, and the fork is withdrawed at last, accomplishes the goods and places at goods shelves action flow.
When the stacker gets and puts goods in-process and the stacker moves, the appearance of the goods needs to be detected through the external inspection frame in real time, and the accidents that the appearance of the goods exceeds the limit and collides with the stacker cargo carrying platform frame or the goods shelf are prevented. At present, in order to meet the industrial 4.0 flexible production requirement and the universality of goods storage in the vertical warehouse, the utilization rate of the vertical warehouse is improved, the production cost is reduced, and goods with various external dimensions can be stored in one vertical warehouse. However, the prior art has the following technical problems:
1) a fixed photoelectric shape detection method comprises the following steps: the traditional method for detecting the fixed shape of the cargo carrying platform is not suitable for the requirements of industrial 4.0 flexible production and the universality of vertical warehouse cargo storage, because the detection is photoelectrically fixed, the limited safe area of the shape of the cargo is fixed and unchangeable, and the detection requirements of the shapes of various cargos cannot be met. If only the maximum goods size is used as the over-limit judgment basis, the regular appearance of the small-size goods cannot be ensured, and the condition that the small-size goods topple and incline cannot be detected.
2) Limitations of photoelectric profile detection: according to the prior art scheme, aiming at goods with multiple specifications and models in a stereoscopic warehouse, multiple groups of detection photoelectricity are required to be arranged to cooperate with goods appearance detection, program development is required to be carried out according to goods appearance size and goods location size, and logic of the goods appearance detection is executed, so that on one hand, the problems caused by the mode are that multiple groups of photoelectricity are simultaneously installed on a goods carrying table with limited space, mechanical design installation difficulty and electrical wiring difficulty are increased, meanwhile, aiming at different situations on site, the irradiation angle of the photoelectricity needs to be adjusted, the difficulty of adjusting the photoelectricity is multiplied by the increase of the number, and the influence between the photoelectricity and the photoelectricity needs to be avoided; on the other hand, the increase of the photoelectric quantity inevitably leads to the increase of the complexity of the program logic, more program development time and debugging time are needed, and the overall stability of the system is reduced along with the increase of peripheral devices.
Aiming at the technical problems, the technical scheme provides a visual camera appearance detection scheme, and is combined with a telescopic goods shelf system, so that the problem of difficult flexible storage in the goods taking and placing process of the stacker is perfectly solved.
Disclosure of Invention
A goods taking and placing system of a stacker comprises an upper computer, the stacker, goods, a tray, a goods shelf and a PLC control unit;
the upper computer can send goods outline size data, namely the width W, the height H and the depth D of the goods outline to the stacker;
the stacker is used for receiving the goods outline dimension data sent by the upper computer and executing a goods picking and placing program; the stacker comprises a cargo carrying table, a cargo fork and a cargo shape detection system based on visual camera ranging; the cargo shape detection system based on the visual camera ranging is arranged on the cargo carrying platform; the fork is arranged at the bottom end of the cargo carrying table and consists of two forks, a transmission shaft and a fork motor, the two forks are connected through the transmission shaft, the fork motor is connected to the bottom ends of the forks, transmission gears are arranged on the fork motor and the forks, and when the forks are completely retracted and are in the middle position on the cargo carrying table, the fork is defined as the original point of the forks;
the goods are placed on the tray, two goods grooves are formed in the lower portion of the tray, and the goods forks can be placed in the goods grooves;
the goods shelf is used for storing goods and comprises a fixed goods shelf and a telescopic goods shelf;
the PLC control unit is arranged on the cargo carrying platform and is used for system control and alarm output; the PLC control unit is connected with a motor driver and used for controlling the operation of a motor, and the motor driver is matched with the fork motor and used for outputting electric energy to drive the fork motor;
the cargo shape detection system based on visual camera ranging comprises five visual cameras, wherein the visual cameras are connected with a PLC (programmable logic controller) control unit and used for carrying out data interaction; the goods carrying platform is provided with an external inspection frame, the top of the goods carrying platform is respectively provided with a left visual camera and a right visual camera on left and right beams of the external inspection frame in the telescopic direction of the fork, the front visual camera and the rear visual camera are respectively arranged on the front side and the rear side of the external inspection frame of the goods carrying platform in the walking direction of the stacker, the center of the top of the goods carrying platform is provided with a lifting mechanism, the lifting mechanism is provided with a top visual camera, and the lifting mechanism drives the top visual camera to lift between a high position and a low position when in operation so as to adjust the picture capturing range of the top visual camera;
furthermore, the telescopic goods shelf is arranged at the upper end of the left side or/and the right side or/and the top of the fixed goods shelf, and the fixed goods shelf is fixedly connected with the upright post or/and the cross beam of the telescopic goods shelf; the telescopic goods shelf consists of more than one independent adjustable goods shelf unit; the upright columns and the cross beams of the adjustable shelf units are composed of cylindrical telescopic rods or telescopic chute rods, and the cylindrical telescopic rods or the telescopic chute rods are fixedly connected with the end parts of the adjacent cylindrical telescopic rods or the telescopic chute rods; the telescopic driving mechanism is arranged on the cylindrical telescopic rod or the telescopic sliding chute rod and driven by a motor to drive the cylindrical telescopic rod or the telescopic sliding chute rod to stretch in the vertical or horizontal direction, so that the height, the width and the depth of the shelf are adjusted.
The application method of the system comprises the following steps,
the method comprises the following steps: scheduling tasks of the upper computer;
the upper computer records the cargo information, sends the task to the stacker to execute the cargo warehousing task, and the cargo information comprises initial data of the appearance of the cargo and is marked as W0H 0D 0;
step two: scanning goods shape data and detecting the shape of the goods when the goods enter a goods carrying table;
the stacker executes a goods taking program, after the goods and the stacker are in place, the visual camera starts to detect the shape data of the goods, the visual camera can also finish the identification of the pallet bar code and store information for later use while scanning the shape size of the goods;
the cargo shape data scanning step comprises: firstly, a lifting mechanism positioned at the top of a cargo carrying platform drives a top vision camera to lift, and the top vision camera starts to work after reaching a high position; secondly, before the stacker starts to fork and take goods, the left vision camera scans goods on the right side of the goods loading platform or the right vision camera scans goods on the left side of the goods loading platform to obtain the actual overall dimension width W1 and the height H1 of the goods, the relationship between the actual overall dimension data of the goods and the allowable threshold value of the frame of the goods loading platform is analyzed and judged by analyzing the width W1 and the height H1 of the overall dimension data of the goods, and the conclusion whether the overall dimension of the goods exceeds the limit is obtained according to the comparison result; when the actual external dimension width W1 or height H1 of the goods exceeds the allowable threshold value of the loading platform frame, the PLC control unit outputs an alarm, and the task of the stacker is terminated; meanwhile, the stacker feeds back the pallet bar code information of the current goods to the upper computer, and reminds the upper computer to carry out exception handling on the pallet and the goods; when the width W1 and the height H1 do not overload the maximum threshold value of the goods platform frame, the stacker starts to fork and take goods; in the process that the goods enter the goods carrying platform, the top vision camera, the front vision camera, the rear vision camera, the left vision camera and the right vision camera continuously work to dynamically detect the regularity of the appearance of the goods; when the goods are forked back to the original point and the goods are completely retracted to the goods loading platform, the top vision camera also completes data acquisition of the goods depth D1, so that the visual camera finishes the goods outline size acquisition, and the actual outline size W1H 1D 1 of the goods is obtained;
respectively subtracting the actually measured goods shape data W1H 1D 1 and the initial data W0H 0D 0 from the three directions of width, height and depth, and when the absolute value of any one group of difference results of the three data exceeds an error range m (m is greater than 0), determining that the goods shape data is abnormal, outputting an alarm by a PLC (programmable logic controller) control unit, and executing the step four to process the goods with the problem of overrun by the stacker;
step three: detecting the appearance of the goods in the target goods space in an overrun way;
if the absolute value of the difference between the actual cargo external dimension W1H 1D 1 and the initial external dimension W0H 0D 0 does not exceed the error range m (m >0), the PLC control unit reads the warehousing target cargo space volume W2H 2D 2 and the cargo space design allowance n (n >0) designated by the upper computer; respectively carrying out difference on W2 and W1, H2 and H1, and D2 and D1, respectively comparing the three results with n, if the difference result of each of the three items is greater than the design allowance n, the overall dimension of the goods does not exceed the volume of the specified goods position, and continuously executing a goods placing program by the stacker to place the goods to the specified goods position; if one of the three items is poor and the result is less than the design allowance n, the external dimension of the goods is considered to exceed the volume of the specified goods location, namely the specification of the goods is not matched with the specified goods location, the external dimension of the goods exceeds the allowable dimension of the goods location, and the stacker executes the fourth step to process the goods with the problem of overrun;
step four: processing the problem of the appearance overrun of the goods;
when the goods overrun alarm occurs, the PLC control unit controls the telescopic goods shelf to act, the allowable space of an idle goods position in the telescopic goods shelf is adjusted to the size matched with the actual overall dimension of the current goods, and then the goods with overrun problem are placed in the goods position; meanwhile, the PLC control unit packs and sends the information of the goods tray and the actual physical dimension data information of the goods to an upper computer, and the upper computer screens the problems and distributes new goods positions and then moves the goods to a specified position from the telescopic goods shelf.
In conclusion, the invention collects the goods appearance pictures of different time periods in the goods taking process of the stacker and calculates the actual appearance size of the goods; actual overall dimension data obtained through measurement is compared with cargo overall dimension data and cargo space volume information sent by an upper computer, and therefore detection of cargoes of different overall dimensions is achieved. The specific working principle is as follows: the upper computer sends a task scheduling instruction of taking and placing goods; the stacker carries out picking and placing procedures of corresponding goods according to the instruction; in the process of taking and placing the stacker, the overrun detection of the actual overall dimension of the goods is involved twice, the first time is the detection that whether the actual overall dimension of the goods in the goods taking of the stacker exceeds the allowable limit of a goods carrying platform frame, the second time is the detection that the goods taking of the stacker succeeds, and when the goods are planned to be placed, whether the actual overall dimension of the goods exceeds the capacity limit of a target goods space; through transfinite detection, the final purpose is to solve the processing of problem goods under the goods actual dimension surpasss the target goods position volume condition, through the scalable goods shelves of PLC control unit control promptly, through the length, width or the height of adjusting scalable goods shelves, with transfinite problem goods and pre-put scalable goods shelves region to wait subsequent upper computer goods position reallocation.
The invention can effectively solve the problem that the appearance of the flexible storage goods in the stereoscopic warehouse is out of limit, replaces a plurality of groups of photoelectric detection goods appearance sizes with the visual cameras, improves the precision and the efficiency, and has consistent program interfaces and improves the operation stability of the system because the same set of visual camera detection system detects the goods with various specifications. By applying the method, on the basis of simply and efficiently completing the detection of the shape overrun of the goods, the tray bar code scanning and the actual physical dimension data scanning of the goods are used for sending the tray information and the goods shape data of the goods with the problem of the shape overrun of the goods to the upper computer, and the upper computer carries out self-diagnosis, screens the problems and processes the problems, so that the automatic processing of the fault of the shape overrun of the goods without manual intervention is realized, the fault processing efficiency and the logistics turnover efficiency are improved, the labor cost is reduced, and the intelligent logistics is really realized.
Drawings
FIG. 1 is a top view of the cargo bed of the present invention.
Figure 2 is a front view of the cargo bed of the present invention.
FIG. 3 is a main flow chart of the stacker pick and place system of the present invention.
Detailed Description
With reference to figures 1, 2 and 3,
a goods taking and placing system of a stacker comprises an upper computer, the stacker, goods, a tray, a goods shelf and a PLC control unit;
the upper computer can send goods appearance size data, namely the width W, the height H and the depth D of the goods appearance to the stacker;
the stacker is used for receiving the goods outline dimension data sent by the upper computer and executing a goods picking and placing program; the stacker comprises a cargo carrying table, a cargo fork and a cargo shape detection system based on visual camera ranging;
the goods appearance detection system based on the visual camera ranging is arranged on the goods carrying platform; the cargo shape detection system based on visual camera ranging comprises five visual cameras, wherein the visual cameras are connected with a PLC (programmable logic controller) control unit and used for carrying out data interaction; the goods carrying platform is provided with an external inspection frame, the top of the goods carrying platform is provided with a left visual camera 1 and a right visual camera 2 on left and right beams of the external inspection frame in the telescopic direction of the fork, the front visual camera 3 and the rear visual camera 4 are respectively arranged on the front side and the rear side of the external inspection frame of the goods carrying platform in the walking direction of the stacker, the center of the top of the goods carrying platform is provided with a lifting mechanism, the lifting mechanism is provided with a top visual camera 5, and the lifting mechanism drives the top visual camera 5 to ascend and descend between a high position 6 and a low position 7 when in operation, so as to adjust the picture capturing range of the top visual camera 5;
the pallet fork is arranged at the bottom end of the pallet loading platform and consists of two pallet forks, a transmission shaft and a pallet fork motor, the two pallet forks are connected through the transmission shaft, the pallet fork motor is connected at the bottom end of the pallet fork, transmission gears are arranged on the pallet fork motor and the pallet fork, and when the pallet fork is completely retracted and is centered on the pallet loading platform, the pallet fork is defined as the original point of the pallet fork;
the goods are placed on the tray, two goods grooves are formed in the lower portion of the tray, and the goods forks can be placed in the goods grooves;
the goods shelf is used for storing goods and comprises a fixed goods shelf and a telescopic goods shelf; the telescopic goods shelf is arranged at the left side or/and the right side or/and the upper end of the top of the fixed goods shelf, and the fixed goods shelf is fixedly connected with the upright post or/and the cross beam of the telescopic goods shelf; the telescopic goods shelf consists of more than one independent adjustable goods shelf unit; the upright columns and the cross beams of the adjustable shelf units are composed of cylindrical telescopic rods or telescopic chute rods, and the cylindrical telescopic rods or the telescopic chute rods are fixedly connected with the end parts of the adjacent cylindrical telescopic rods or the telescopic chute rods; the telescopic driving mechanism is arranged on the cylindrical telescopic rod or the telescopic sliding chute rod and driven by a motor to drive the cylindrical telescopic rod or the telescopic sliding chute rod to stretch in the vertical or horizontal direction, so that the height, the width and the depth of the shelf are adjusted.
The PLC control unit is arranged on the cargo carrying platform and is used for system control and output alarm; the PLC control unit is connected with a motor driver to control the motor to run, and the motor driver is matched with the fork motor and used for outputting electric energy to drive the fork motor.
The following are specific examples of four cases:
example one abnormal goods removal
The initial data information W0H 0D 0 of the goods is 1000mm 1200mm 1000mm, and the frame threshold of the loading platform is 1200mm 1300mm 1200 mm;
the method comprises the following steps: scheduling tasks of the upper computer;
the upper computer records initial goods data information W0H 0D 0 as 1000mm 1200mm 1000mm, and sends the task to the stacking machine to execute the goods warehousing task;
step two: scanning goods shape data and detecting the shape of the goods when the goods enter a goods carrying table;
the left vision camera 1 scans goods on the right side of the goods loading platform or the right vision camera 2 scans goods on the left side of the goods loading platform to obtain the actual overall dimension width W1=1002mm and the height H1=1332mm of the goods, the analysis and judgment of the size relationship between the width W1=1002mm and the height H1=1332mm and the allowable threshold value 1200mm x 1300mm x 1200mm of the frame of the goods loading platform is carried out, the result is that the height H1 of the goods exceeds the allowable threshold value of the frame of the goods loading platform, the PLC control unit outputs an alarm, and at the moment, the task of the stacker is terminated; meanwhile, the stacker feeds back the pallet bar code information of the current goods to the upper computer, and reminds the upper computer to carry out exception handling on the pallet and the goods.
In the second embodiment, the absolute value of the difference between the actual overall dimension of the goods and the initial data exceeds the error range m, and the goods are placed on the telescopic goods shelf as abnormal goods
The goods initial data information W0H 0D 0 is 1000mm 1200mm 1000mm, the loading platform frame threshold value is 1200mm 1300mm 1200mm, and m =50 mm;
the method comprises the following steps: scheduling tasks of the upper computer;
the upper computer records cargo information W0H 0D 0 as 1000mm 1200mm 1000mm, and sends the task to the stacking machine to execute the cargo warehousing task;
step two: scanning goods shape data and detecting the shape of the goods when the goods enter a goods carrying table;
the left visual camera 1 scans goods on the right side of the goods loading platform or the right visual camera 2 scans goods on the left side of the goods loading platform to obtain the size relation between the actual overall dimension width W =1002mm and the height H =1120mm of the goods, the width W =1002mm and the height H =1120mm and the allowable threshold value 1200mm of the frame of the goods loading platform 1300mm 1200mm are analyzed and judged to obtain that the actual width W1 or the height H1 of the goods do not exceed the allowable threshold value of the frame of the goods loading platform, the stacker starts to fork and take the goods, and in the process that the goods enter the goods loading platform, the five visual cameras continuously work to dynamically detect the overall regularity of the goods; when the goods are forked back to the original point and the goods are completely retracted to the goods loading platform, the top vision camera 5 acquires the goods depth D1, so that the external dimension of the goods acquired by the vision camera is completed, and the actual external dimension W1H 1D 1 of the goods is 1002mm 1120mm 1000 mm;
respectively subtracting W1H 1D 1 and W0H 0D 0 from the width direction, the height direction and the depth direction to obtain absolute values, wherein the absolute value of the difference value of the height H is 80mm, the error range m =50mm is exceeded, the PLC control unit outputs an alarm when the goods appearance data is considered to be abnormal, and the stacker executes the step four to process the goods with the problem of exceeding the limit;
step four: processing the problem of the appearance overrun of the goods;
the PLC control unit controls the telescopic goods shelf to act to adjust the allowable space of an idle goods position in the telescopic goods shelf to a size matched with the actual overall dimension of the current goods, and then the problem goods are placed in the goods position; meanwhile, the PLC control unit packs and sends the information of the goods tray and the actual physical dimension data information of the goods to an upper computer, and the upper computer screens the problems and distributes new goods positions and then moves the goods to a specified position from the telescopic goods shelf.
Example three goods are put into the target goods space
The goods initial data information W0H 0D 0 is 1000mm 1200mm 1000mm, the loading platform frame threshold value is 1200mm 1300mm 1200mm, m =50mm, and n is larger than 0;
the method comprises the following steps: scheduling tasks of the upper computer;
the upper computer records cargo information W0H 0D 0 as 1000mm 1200mm 1000mm, and the stacker executes cargo warehousing tasks;
step two: scanning goods shape data and detecting the shape of the goods when the goods enter a goods carrying table;
the left visual camera 1 scans goods on the right side of the goods loading platform or the right visual camera 2 scans goods on the left side of the goods loading platform to obtain the actual overall dimension width W1=1002mm and the height H1=1220mm of the goods, the analysis judges that the width W1=1002mm and the height H1=1220mm are in the size relation with the allowable threshold value 1200mm x 1300mm x 1200mm of the frame of the goods loading platform, the width W1 or the height H1 does not exceed the allowable threshold value of the frame of the goods loading platform, the stacker starts to fork and take the goods, and in the process that the goods enter the goods loading platform, the five visual cameras continuously work to dynamically detect the regularity of the appearance of the goods; when the goods are forked back to the original point and the goods are completely retracted to the goods loading platform, the top vision camera 5 acquires the goods depth D1, so that the external dimension of the goods acquired by the vision camera is completed, and the actual external dimension W1H 1D 1 of the goods is 1002mm 1220mm 1000 mm;
step three: detecting the appearance of the goods in the target goods space in an overrun way;
making absolute differences between W1H 1D 1 and W0H 0D 0 from the three directions of width, height and depth respectively, wherein the absolute difference between W1H 1D 1 and W0H 0D 0 does not exceed an error range m, a PLC control unit reads a warehousing target cargo space volume W2H 2D 2 and a cargo space design margin n specified by an upper computer, and the target cargo space volume W2H 2D 2 is 1200mm 1400mm 1200 mm; and respectively carrying out difference on W2 and W1, H2 and H1, and D2 and D1, comparing the three results with n, wherein the difference result of each of the three items is larger than n, and continuously executing the goods placing program by the stacker to place the goods in the designated goods space.
The actual overall dimension of the four goods exceeds the target goods volume and are placed on a telescopic goods shelf
The goods initial data information W0H 0D 0 is 1000mm 1200mm 1000mm, the loading platform frame threshold value is 1200mm 1300mm 1200mm, m =50mm, and n is larger than 0;
the method comprises the following steps: scheduling tasks of the upper computer;
the upper computer records cargo information W0H 0D 0 as 1000mm 1200mm 1000mm, and sends the task to the stacking machine to execute the cargo warehousing task;
step two: scanning goods shape data and detecting the shape of the goods when the goods enter a goods carrying table;
the left vision camera 1 scans goods on the right side of the goods loading platform or the right vision camera 2 scans goods on the left side of the goods loading platform to obtain the actual overall dimension width W1=1002mm and the height H1=1220mm of the goods, the analysis judges that the width W1=1002mm and the height H1=1220mm are in the size relation with the allowable threshold value 1200mm x 1300mm x 1200mm of the goods loading platform frame, the width W1 or the height H1 do not overload the maximum threshold value of the goods loading platform frame, and the stacker starts to fork and take the goods; in the process that the goods enter the goods carrying platform, the five visual cameras continuously work to dynamically detect the regularity of the appearance of the goods; when the goods are forked back to the original point and the goods are completely retracted to the goods loading platform, the top vision camera 5 acquires the goods depth D1, so that the external dimension of the goods acquired by the vision camera is completed, and the actual external dimension W1H 1D 1 of the goods is 1002mm 1220mm 1000 mm;
step three: detecting the appearance of the goods in the target goods space in an overrun way;
making absolute differences between W1H 1D 1 and W0H 0D 0 from the three directions of width, height and depth to obtain absolute values, wherein the absolute difference values of W1H 1D 1 and W0H 0D 0 do not exceed an error range m, and the PLC control unit reads the warehousing target cargo space volume W2H 2D 2 specified by the upper computer to be 1180mm 1200mm 1180mm and a cargo space design margin n; respectively carrying out difference on W2 and W1, H2 and H1, and D2 and D1, respectively comparing the three results with n, wherein the difference result of the height H is smaller than the design allowance n, the overall dimension of the goods exceeds the volume of the designated goods space, and the stacker executes the fourth step to process the goods with the problem of overrun;
step four: processing the problem of the appearance overrun of the goods;
the PLC control unit controls the telescopic goods shelf to act, the allowable space of an idle goods position in the telescopic goods shelf is adjusted to the size matched with the actual overall dimension of the current goods, and then the goods with the overrun problem are placed in the goods position; meanwhile, the PLC control unit packs and sends the information of the goods tray and the actual physical dimension data information of the goods to an upper computer, and the upper computer screens the problems and distributes new goods positions and then moves the goods to a specified position from the telescopic goods shelf.
Claims (3)
1. A goods taking and placing system of a stacker comprises an upper computer, the stacker, a tray, a goods shelf and a PLC control unit;
the upper computer sends goods outline size data, namely the width W, the height H and the depth D of the goods outline to the stacker;
the stacker is used for receiving the goods outline dimension data sent by the upper computer and executing a goods picking and placing program; the stacker comprises a cargo carrying table, a cargo fork and a cargo shape detection system based on visual camera ranging; the cargo shape detection system based on the visual camera ranging is arranged on the cargo carrying platform; the fork is arranged at the bottom end of the cargo carrying platform, and when the fork is arranged in the middle of the cargo carrying platform, the fork is defined as the original point of the fork;
the pallet is used for placing goods, two goods grooves are formed in the lower portion of the pallet, and the goods forks can be placed in the goods grooves;
the goods shelf is used for storing goods and comprises a fixed goods shelf and a telescopic goods shelf;
the PLC control unit is arranged on the cargo carrying platform and is used for system control and alarm output;
the method is characterized in that: the cargo shape detection system based on visual camera ranging comprises five visual cameras, wherein the visual cameras are connected with a PLC (programmable logic controller) control unit; an external inspection frame is arranged on the cargo carrying platform, a left visual camera (1) and a right visual camera (2) are respectively arranged on a left cross beam and a right cross beam of the external inspection frame, a front visual camera (3) and a rear visual camera (4) are respectively arranged on the front side and the rear side of the external inspection frame, a lifting mechanism is arranged in the center of the top of the cargo carrying platform, a top visual camera (5) is arranged on the lifting mechanism, the lifting mechanism drives the top visual camera to lift between a high position and a low position, and the picture capturing range of the top visual camera is adjusted; the telescopic goods shelf is arranged at the left side or/and the right side or/and the upper end of the top of the fixed goods shelf, and the fixed goods shelf is fixedly connected with the upright post or/and the cross beam of the telescopic goods shelf; the telescopic goods shelf consists of more than one independent adjustable goods shelf unit; the upright columns and the cross beams of the adjustable shelf units are composed of cylindrical telescopic rods or telescopic chute rods, and the cylindrical telescopic rods or the telescopic chute rods are fixedly connected with the end parts of the adjacent cylindrical telescopic rods or the telescopic chute rods; the telescopic driving mechanism is arranged on the cylindrical telescopic rod or the telescopic sliding chute rod and driven by a motor to drive the cylindrical telescopic rod or the telescopic sliding chute rod to stretch in the vertical or horizontal direction, so that the height, the width and the depth of the shelf are adjusted.
2. The method for applying the stacker pick-and-place system according to claim 1, wherein: the method comprises the following steps:
the method comprises the following steps: scheduling tasks of the upper computer;
the upper computer records the cargo information, sends the task to the stacker to execute the cargo warehousing task, and the cargo information comprises initial data of the appearance of the cargo and is marked as W0H 0D 0;
step two: scanning goods shape data and detecting the shape of the goods when the goods enter a goods carrying table;
when the stacker executes the goods taking program process, the visual camera detects the actual shape data of the goods, and the actual shape data is marked as W1H 1D 1; meanwhile, the visual camera identifies the bar code information of the tray and stores the bar code information for later use; making differences between W1 and W0, between H1 and H0, and between D1 and D0, when the absolute value of any one of the differences exceeds an error range m, and m is greater than 0, determining that the goods appearance data is abnormal, outputting an alarm by a PLC control unit, and processing the goods with the problem of overrun by the stacker in the fourth step;
step three: detecting the appearance of the goods in the target goods space in an overrun way;
if the absolute value of the difference between the actual external shape data W1H 1D 1 and the initial data W0H 0D 0 does not exceed the error range m, m is greater than 0, the PLC control unit reads the warehousing target cargo space volume W2H 2D 2 and the cargo space design allowance n, n is greater than 0, wherein the warehousing target cargo space volume W2H 2D 2 is specified by the upper computer; respectively carrying out difference on W2 and W1, H2 and H1, and D2 and D1, respectively comparing the three results with n, if the difference result of each of the three items is greater than the design allowance n, the overall dimension of the goods does not exceed the volume of the specified goods position, and continuously executing a goods placing program by the stacker to place the goods to the specified goods position; otherwise, the stacker executes the fourth step to process the goods with the overrun problem;
step four: processing the problem of the appearance overrun of the goods;
when the goods overrun alarm occurs, the PLC control unit controls the telescopic goods shelf to act, the allowable space of an idle goods position in the telescopic goods shelf is adjusted to the size matched with the actual overall dimension of the current goods, and then the goods with overrun problem are placed in the goods position; meanwhile, the PLC control unit packs and sends the information of the goods tray and the actual physical dimension data information of the goods to an upper computer, and the upper computer screens the problems and distributes new goods positions and then moves the goods to a specified position from the telescopic goods shelf.
3. The method for applying the stacker picking and placing system according to claim 2, wherein: the scanning of the cargo shape data in the second step comprises the following steps: the lifting mechanism drives the top vision camera (5) to reach a high position (6), and the top vision camera (5) starts to work; before the stacker stretches and forks to take goods, a left vision camera (1) scans the goods positioned on the right side of a loading platform or a right vision camera (2) scans the goods positioned on the left side of the loading platform to obtain the actual overall dimension width W1 and the height H1 of the goods, the size relation between the width W1 and the height H1 and the allowable threshold value of a loading platform frame is analyzed and judged, when the width W1 or the height H1 exceeds the allowable threshold value of the loading platform frame, a PLC (programmable logic controller) outputs an alarm, the task of the stacker is terminated at the moment, meanwhile, the stacker feeds back the current pallet bar code information of the goods to an upper computer, and the upper computer carries out exception processing on the pallet and the goods; when the width W1 and the height H1 do not overload the maximum threshold value of the goods platform frame, the stacker starts to fork and take goods; in the process that the goods enter the goods carrying platform, the five visual cameras continuously work to dynamically detect the regularity of the appearance of the goods; when the fork returns to the original point, the top vision camera (5) finishes the data acquisition of the cargo depth D1, and the visual camera finishes the acquisition of the actual overall dimensions of the cargo, which is marked as W1H 1D 1.
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