CN114289346B - Automatic grouping method for lightning arrester resistor discs - Google Patents
Automatic grouping method for lightning arrester resistor discs Download PDFInfo
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- CN114289346B CN114289346B CN202210065362.3A CN202210065362A CN114289346B CN 114289346 B CN114289346 B CN 114289346B CN 202210065362 A CN202210065362 A CN 202210065362A CN 114289346 B CN114289346 B CN 114289346B
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Abstract
The application relates to the technical field of lightning arrester resistor disc matching, and relates to an automatic lightning arrester resistor disc matching method, which comprises the following steps: the central control system is used for receiving and transmitting relevant parameter configuration and communication instructions in the resistor disc allocation and sorting process; the identifying and warehousing system is used for identifying the code spraying information of the resistor disc on the conveying line, warehousing and archiving, and warning and rejecting unqualified resistor discs; the intelligent grouping system is used for intelligently grouping qualified resistor discs on the conveying line to form a resistor disc grouping list meeting the requirements; the sorting and dispatching system is used for sorting and dispatching the resistor sheets on the conveying line, sorting the assembled resistor sheets, turning the unassigned resistor sheets, and cleaning the failed resistor sheets; and the manual intervention system is used for performing manual intervention when individual resistance sheets are subjected to multiple recognition errors under sorting vision and sorting efficiency is affected. The automatic grouping method can realize intelligent grouping and automatic sorting of the resistor chips, improves production efficiency, reduces production cost and improves product quality.
Description
Technical Field
The invention relates to the technical field of lightning arrester resistor disc matching, in particular to an automatic lightning arrester resistor disc matching method.
Background
The lightning arrester matching and grouping procedure is to test the resistor disc, measure the performance parameter of each resistor disc, code the parameter information to the surface of the resistor disc by using a code spraying machine, record, arrange and group calculate the information on the resistor disc manually, find the resistor disc with the corresponding parameter manually based on the matching list and sort. The traditional grouping and sorting procedure completely depends on manpower, and has the problems of low production efficiency, high labor cost, large manual error and the like.
Disclosure of Invention
The purpose of this application is to provide an arrester resistance card automatic allocation group method, can realize the automatic allocation group and the letter sorting of arrester resistance card, improve production efficiency, reduction in production cost promotes product quality. The application is realized by adopting the following technical scheme:
the application provides an automatic distribution and grouping method of lightning arrester resistance card, which is applied to an automatic distribution and grouping system of the lightning arrester resistance card, wherein the automatic distribution and grouping system of the lightning arrester resistance card comprises a central control system, an identification warehouse system, an intelligent distribution and grouping system and a sorting and dispatching system, the method is used for controlling distribution and grouping equipment of the lightning arrester resistance card so that the distribution and grouping equipment of the lightning arrester resistance card can automatically distribute and group the resistance card to be distributed, the distribution and grouping equipment of the lightning arrester resistance card comprises a conveying line for conveying the resistance card and a sorting robot for operating the resistance card, and the method comprises the following steps:
The identification warehousing system identifies code spraying information of the resistor disc to be assembled on the conveying line and sends the code spraying information to the central control system;
the central control system stores the code spraying information in a warehouse, determines the parameter information of the resistor disc to be assembled according to the code spraying information, and determines whether the resistor disc to be assembled is qualified according to the parameter information;
when the central control system judges that the resistor sheets to be assembled are unqualified, the rejecting equipment is controlled to reject the resistor sheets to be assembled, the resistor sheets to be assembled are marked as rejected resistor sheets, when the resistor sheets to be assembled are judged to be qualified, the resistor sheets to be assembled are marked as non-assembled resistor sheets, and statistics is carried out on the non-assembled resistor sheets;
the intelligent grouping system intelligently groups each unassigned resistor on the conveying line according to a grouping rule to form a resistor grouping list meeting requirements;
and the sorting and dispatching system controls the sorting robot to sort and group the non-group resistance cards on the conveying line according to the group list.
Optionally, the grouping rule includes: the single group of the resistor pieces comprises the number S of the resistor pieces and the sum S of the U1mA corresponding to each resistor piece in the single group of the resistor pieces u1ma The number of the resistor pieces included in each group of resistor pieces is less than or equal to S;
the non-assembled resistor discs are intelligently assembled according to an assembling rule to form a resistor disc assembling list meeting requirements, and the intelligent resistor disc assembling method comprises the following steps:
step S1, when new code spraying information is detected to be put in storage, counting the number N of unassigned resistor discs in a database;
step S2, if the number N of the unassigned resistor sheets is greater than or equal to the number S of the single set of resistor sheets in the pairing rules, ordering the unassigned resistor sheets according to U1mA, selecting S unassigned resistor sheets from the N unassigned resistor sheets according to the ordering, and calculating the sum T of S U1mA corresponding to the S unassigned resistor sheets u1ma When T u1ma Closest to S u1ma When the selected S unassigned resistor sheets are marked as a combination G;
step S2, replacing at least one resistor in the combination G by the resistor outside the combination G based on a preset replacement principle to obtain a replaced combination G, wherein the preset replacement principle is as follows: each resistor sheet in the combination g satisfies the following expression H: s is S u1ma х(1-D) <＝ T u1ma <＝S u1ma *(1+D)；
Step S3, if the sum of residual voltages of the resistor sheets in the combination g is smaller than the upper limit C of residual voltages in the matching rule max Judging that the group matching is successful, marking each resistor sheet state in the combination g as the matched group, and adding 1 to the group code;
Step S4, if the sum of residual voltages of the resistor sheets in the combination g is more than or equal to the upper residual voltage limit C max Judging that the grouping fails;
step S5, if the expression H cannot be satisfied, and T u1ma <S u1ma * (1-D) determining that the pairing fails;
in step S6 of the process,if the expression H cannot be satisfied, and T u1ma >S u1ma * (1+d) reducing the number of the single group of resistor sheets S to make s=s-1, and repeating the steps S2 to S6;
and S7, if the matching fails, waiting for the next new resistor disc to be put in storage, and then carrying out the steps S1 to S7.
Optionally, the method further comprises:
step S8, if the grouping is successful, when the grouping has been formed, the number N of groups grp Less than the sorting robot number O, N grp <O, the identification B of the single group is obtained i Marked as 1, otherwise single group is identified as B i Is 0;
the step S2 is preceded by the following step S9:
if single group is configured with group identification B i When the number N of the unassigned resistive patches is greater than or equal to the sorting robot number O multiplied by the number S of the single-set resistive patches, namely N>When=o×s, determining to perform grouping; if B is i When the number N of the unassigned resistor is greater than or equal to the number S of the single-group resistor, namely N>When S, determining to perform grouping; when it is determined to perform grouping, step S2 is performed.
Optionally, the lightning arrester resistor disc allocation device further comprises a sorting vision device for identifying the resistor discs located in the sorting vision area;
The sorting robot is controlled to sort and group the unassigned resistor sheets on the conveying line according to the grouping list, and the sorting robot comprises the following steps:
step S01, when the resistor sheets on the conveying line pass through the sorting vision area, the sorting vision equipment identifies code spraying information of the resistor sheets in the sorting vision area and transmits the identified code spraying information to the central control system;
step S02, the central control system searches a database for a resistor sheet consistent with the code spraying information received from the sorting vision equipment;
step S03, if the central control system does not find the resistor sheet consistent with the code spraying information received from the sorting vision equipment, judging that the code spraying information of the resistor sheet is wrong in recognition, sending a command of grabbing to a rotary line to the sorting robot, and after a specific time, sending a rotary line inflow command by the central control system to enable the resistor sheet with wrong recognition to reenter the sorting vision area for recognition;
and step S04, if the resistor disc consistent with the code spraying information received from the sorting vision equipment is found, the state of the resistor disc is the matched group, the group code corresponding to the found resistor disc is the current sorting output group, the central control system issues an instruction for grabbing the resistor disc to a tray and sorting position coordinates to the sorting robot, and the state of the resistor disc is marked as sorted after the sorting robot finishes grabbing.
Optionally, the method further comprises the steps of:
step S05, if a resistor piece consistent with the code spraying information received from the sorting vision equipment is found, the state of the resistor piece is unmatched, the unmatched number in a rotary line is larger than the upper limit of the capacity of the rotary line, a cleaning instruction and a cleaning position coordinate are issued to the sorting robot by the central control system, the state of the resistor piece is marked as cleaned by the central control system after the cleaning action of the sorting robot is completed, and the unmatched number in the rotary line is reduced by 1;
step S06, if a resistor piece consistent with the code spraying information received from the sorting vision equipment is found, and the state of the found resistor piece is unassigned, but the unassigned number in a revolving line does not reach the upper limit of the capacity of the revolving line, the central control system issues a command of grabbing to the revolving line to the sorting robot, marks that the state of the resistor piece is revolved, and if the resistor piece does not revolve before, adds 1 to the unassigned number in the revolving line;
step S07, if a resistor sheet consistent with the code spraying information received from the sorting vision equipment is found, and the found resistor sheet is the condition except the steps S05 and S06, the central control system issues a command of grabbing to a turning line to the appointed robot, and the state of the resistor sheet is marked as turned;
Step S08, when the resistor sheets on the trays of the arrester resistor sheet grouping equipment are placed for one row, according to the advancing distance configured in the grouping rule, the central control system issues a tray advancing instruction to the PLC equipment of the sorting vision equipment until the trays are full, automatically triggering the tray replacement, and issuing a sorting result to the printer and the RFID system for output by the central control system;
and S09, triggering the tail tray matching in each tray when the time interval between the resistor disc passing through the sorting visual area and the last resistor disc passing through the identification visual area is larger than a specific time, namely, judging that no new resistor disc is input.
Optionally, the method further comprises the steps of:
step S001, when the resistor sheets pass through the sorting vision area, the central control system increases the number of the resistor sheets passing through the sorting vision area by 1, and counts the number C of the resistor sheets passing through the sorting vision area out And the number of sorted resistance C cur ；
Step S002, the central control system searches the database for the maximum coding interval V of the two continuous resistance sheets of the current sorting group, if the difference between the number of resistance sheets passing through the sorting vision area and the number of sorted resistance sheets is greater than the maximum coding interval V of the two continuous resistance sheets of the current sorting group plus the grouping number S, namely C out -C cur >V+S, judging that manual intervention is needed, and executing step S003;
step S003, the central control system issues a pause instruction to the PLC of the sorting vision equipment, searches the residual resistance sheets to be sorted of the current sorting group in the database, and displays detailed information and corresponding tray information, so that the resistance sheets are manually searched according to the prompt information and placed in the corresponding tray;
step S004, when the fact that the resistor disc is manually placed into the corresponding tray according to the prompt information is monitored, the central control system marks that the resistor disc is sorted, and sends a starting instruction to the PLC.
Optionally, the central control system is further used for determining position coordinates of a resistor piece grabbing point, position coordinates of a resistor piece cleaning point, position coordinates of a resistor piece rotating point, position coordinates of a placing point on a tray when the resistor pieces are sorted and output, the number of the resistor pieces which can be most contained and are not matched with each other on the rotating line body, the advancing distance of the conveying line after each row of resistor pieces are placed, and receiving and issuing communication instructions.
Optionally, the central control system is used for receiving and transmitting relevant parameter configuration and communication instructions in the resistor sheet assembling and sorting process. The configuration items comprise resistor type and basic information, rejection rules of unqualified resistors, and grouping rules of resistors (number S of single group of resistors, sum S of U1mA u1ma Group deviation D, residual pressure upper limit C max ) The position coordinates of the grabbing points of the resistor pieces, the position coordinates of the cleaning points of the resistor pieces, the position coordinates of the rotating points of the resistor pieces, the position coordinates of the placing points on the tray when the resistor pieces are sorted and output, and the maximum number of unassigned resistor pieces which can be accommodated on the rotating line body (the upper limit of the capacity of the rotating line H) max ) The advancing distance of the conveying line after each row of resistor discs are placed, and the IP and the port of the equipment are interacted; communication instruction receiving and issuing comprises communication establishment with interaction equipment such as PLC, industrial vision, robot, printer, RFID and the like and relevant instruction issuing and receiving.
Optionally, the identifying and warehousing system is used for identifying the code spraying information of the resistor disc on the conveying line, warehousing and archiving, and warning and rejecting the unqualified resistor disc. The central control system establishes communication connection with the identification visual equipment and the PLC equipment, the resistor on the conveying line triggers visual identification through an identification area, industrial vision transmits the identified resistor code spraying information to the central control system, the central control system writes the code spraying information into a database for archiving, judges whether the resistor code spraying information accords with a rejection rule, if so, the central control system issues a rejection instruction to the PLC, the PLC performs rejection, the state of the resistor is identified as being rejected, and if not, the state of the resistor is identified as being unassigned;
Optionally, the intelligent matching system is used for intelligent matching of qualified resistance cards on a conveying line, and comprises the following steps:
s1, when new resistance pieces are put in storage, counting the number N of unassigned resistance pieces in a database, and if a single-assembled group identifier B i When the number N of the unassigned resistive patches is equal to or greater than the sorting robot number O multiplied by the number S of the single-group resistive patches, namely N>When=o×s, grouping is performed; if B is i If the number of the unassigned resistors N is equal to or greater than 1, the number of the unassigned resistors N is equal to or greater than the single-group resistorWhen the number of sheets is S, namely N>When S, grouping is performed;
s2, if the number N of the unassigned set of resistance cards is greater than or equal to the number S of the single set of resistance cards, namely N>=s, sorting unassigned resistors by U1mA, calculating to obtain U1mA and closest S u1ma And a resistor sheet combination G of continuous length S, U1mA and T u1ma ；
S3, introducing a matching deviation D, and replacing the external resistor disc in the combination G and the combination to achieve S u1ma *(1-D) <＝ T u1ma <＝S u1ma * (1+D) if the condition is met, and the sum of the residual voltages of the resistor sheets in G is smaller than the upper residual voltage limit C max If the group matching is successful, the state of the resistor disc in the group G is marked as the matched group, the group code is added with 1, and the steps S2 to S3 are repeated; if this condition is met, the sum of residual pressures is equal to or greater than the upper residual limit C max The grouping fails; if the condition is not met, and T u1ma <S u1ma * (1-D) failing the pairing; if the condition is not met, and T u1ma >S u1ma * (1+d) reducing the number of the single group of the resistor sheets S such that s=s-1, repeating S2 to S3;
s4, if the matching is successful, the number of the matched groups N grp Less than the sorting robot number O, N grp <When in O, the single-group configuration group identifier B is modified i 1, otherwise modify single set group identification B i Is 0; and if the group allocation fails, waiting for the next new resistor disc to be put in storage and then carrying out S1 to S4.
The sorting and dispatching system is used for sorting and dispatching the resistor disc on the conveying line and comprises the following steps:
s1, a resistor on a conveying line passes through a sorting vision area, and sorting vision transmits identified resistor code spraying information to a central control system;
s2, the central control system searches a resistor sheet consistent with the code spraying information in a database, if the resistor sheet is not found, the code spraying information of the resistor sheet is wrongly identified, the central control system issues a command of grabbing to a rotary line to a specified robot, and after a specific time, the central control system issues a command of flowing in the rotary line to enable the resistor sheet with the identification error to enter sorting vision again for identification; if the resistor disc meeting the conditions is found, the state of the resistor disc is the matched group, the corresponding group is coded into the current sorting output group, the central control system issues a command for grabbing the resistor disc to a tray and a sorting position coordinate to the appointed robot, and the state of the resistor disc is marked to be sorted after the grabbing is completed; if the resistor sheet meeting the conditions is found, the state of the resistor sheet is unmatched, the unmatched number in the revolving line is larger than the upper limit of the capacity of the revolving line, a central control system issues a cleaning instruction and a cleaning position coordinate to a specified robot, the state of the resistor sheet is marked as cleaned after the cleaning action is completed, and the unmatched number in the revolving line is reduced by 1; if the state of the resistor is unassigned, but the unassigned number in the revolving line does not reach the upper limit of the capacity of the revolving line, the central control system issues a command for grabbing the revolving line to the appointed robot, the state of the resistor is marked to be revolved, and if the resistor is not revolved before, the unassigned number in the revolving line is added with 1; in other cases, the central control system issues a command of grabbing to a turning line to the appointed robot and marks the state of the resistor disc as turned;
S3, when the resistor sheets on the tray are placed in one row, according to the configured advancing distance, the central control system issues a tray advancing instruction to the PLC equipment until the tray is full, automatically triggers the replacement of the tray, and issues a sorting result to the printer and the RFID system for output by the central control system;
s4, when the time interval between the time of sorting the visual area resistor disc and the time of the last visual resistor disc is larger than a specific time, namely, judging that no new resistor disc is input, and triggering the tail disc to be matched.
Optionally, the manual intervention system is used for performing manual intervention when individual resistance sheets are subjected to multiple recognition errors under sorting vision, and sorting efficiency is affected. The method comprises the following steps:
s1, when the resistor pieces pass through the sorting vision area, the number of the resistor pieces passing through the sorting vision is increased by 1, and the number C of the resistor pieces passing through the sorting vision is counted out And the number of sorted resistance C cur The central control system searches the database for the maximum coding interval V of the two continuous resistance sheets of the current sorting group, if the difference between the number of the sorted visual resistance sheets and the number of the sorted resistance sheets is larger than the maximum coding interval of the two continuous resistance sheets of the current sorting groupV plus the number of packets S, i.e. C out -C cur >V+S, judging that manual intervention is needed;
S2, the central control system issues a pause instruction to the PLC, searches the residual resistance cards to be sorted of the current sorting group in the database, and displays detailed information and corresponding tray information;
s3, manually searching a resistor disc according to the prompt information, putting the resistor disc into a corresponding tray, marking the state of the resistor disc as sorted by a central control system, and issuing a starting instruction to a PLC;
s4, sorting out the resistance card, and sorting out the number C of the resistance card cur Increase by 1.
The technical scheme can be seen that the application has the following beneficial effects:
the resistor disc automatic assembling and sorting device can realize automatic assembling and sorting of resistor discs, is automatic in whole flow, does not need manual participation, can reduce labor cost and improves production efficiency.
The resistor disc matching method and device can realize automatic and intelligent matching of the resistor disc, avoid artificial errors, achieve matching optimal solution under the specific sample base number and improve product quality.
The application relates to the technical field of lightning arrester resistor disc matching, and relates to an automatic lightning arrester resistor disc matching method, which comprises the following steps: the central control system is used for receiving and transmitting relevant parameter configuration and communication instructions in the resistor disc allocation and sorting process; the identifying and warehousing system is used for identifying the code spraying information of the resistor disc on the conveying line, warehousing and archiving, and warning and rejecting unqualified resistor discs; the intelligent grouping system is used for intelligently grouping qualified resistor discs on the conveying line to form a resistor disc grouping list meeting the requirements; the sorting and dispatching system is used for sorting and dispatching the resistor sheets on the conveying line, sorting the assembled resistor sheets, turning the unassigned resistor sheets, and cleaning the failed resistor sheets; and the manual intervention system is used for performing manual intervention when individual resistance sheets are subjected to multiple recognition errors under sorting vision and sorting efficiency is affected. The automatic grouping method can realize intelligent grouping and automatic sorting of the resistor chips, improves production efficiency, reduces production cost and improves product quality.
Drawings
FIG. 1 is an overall flow chart of an automatic group allocation method provided herein;
FIG. 2 is a schematic diagram of a central control system of the automatic group allocation method provided in the present application;
FIG. 3 is a flow chart of an identification warehousing system of the automatic group allocation method provided by the present application;
FIG. 4 is a flow chart of an intelligent grouping system of the automated grouping method provided herein;
FIG. 5 is a flow chart of a sort scheduling system of the automated group component sort method provided herein;
fig. 6 is a flow chart of a manual intervention system of the automatic group allocation method provided herein.
Detailed Description
The technical solutions in the present application will be described below with reference to the accompanying drawings. It will be apparent that the described embodiments are only some, but not all, of the embodiments of the present application. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Hereinafter, the terms "first," "second," and the like are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first", "a second", etc. may explicitly or implicitly include one or more such feature.
It should be understood that the foregoing is only intended to assist those skilled in the art in better understanding the embodiments of the present application and is not intended to limit the scope of the embodiments of the present application. Various equivalent modifications and changes will be apparent to those skilled in the art from the foregoing examples, or the combination of any two or more of the foregoing embodiments may be made. Such modifications, variations, or combinations are also within the scope of embodiments of the present application.
It should also be understood that the foregoing description of embodiments of the present application focuses on highlighting differences between the various embodiments and that the same or similar elements not mentioned may be referred to each other and are not described in detail herein for brevity.
It should also be understood that the manner, condition, class and division of the embodiments in the embodiments of the present application are for convenience of description only and should not be construed as being particularly limited, and the various manners, classes, conditions and features of the embodiments may be combined without contradiction.
It is also to be understood that in the various embodiments of the application, terms and/or descriptions of the various embodiments are consistent and may be referenced to one another in the absence of a particular explanation or logic conflict, and that the features of the various embodiments may be combined to form new embodiments in accordance with their inherent logic relationships.
Please refer to fig. 1-6; the invention provides an automatic distribution and grouping method of lightning arrester resistance card, which is applied to an automatic distribution and grouping system of the lightning arrester resistance card, wherein the automatic distribution and grouping system of the lightning arrester resistance card comprises a central control system, an identification warehouse system, an intelligent distribution and grouping system and a sorting and scheduling system, the method is used for controlling a distribution and grouping and sorting device of the lightning arrester resistance card so that the distribution and sorting device of the lightning arrester resistance card can automatically distribute and group the resistance card to be distributed, the distribution and sorting device of the lightning arrester resistance card comprises a conveying line for conveying the resistance card and a sorting robot for operating the resistance card, and the method comprises the following steps:
the identification warehousing system identifies code spraying information of the resistor disc to be assembled on the conveying line and sends the code spraying information to the central control system;
the central control system stores the code spraying information in a warehouse, determines the parameter information of the resistor disc to be assembled according to the code spraying information, and determines whether the resistor disc to be assembled is qualified according to the parameter information;
when the central control system judges that the resistor sheets to be assembled are unqualified, the rejecting equipment is controlled to reject the resistor sheets to be assembled, the resistor sheets to be assembled are marked as rejected resistor sheets, when the resistor sheets to be assembled are judged to be qualified, the resistor sheets to be assembled are marked as non-assembled resistor sheets, and statistics is carried out on the non-assembled resistor sheets;
The intelligent grouping system intelligently groups each unassigned resistor on the conveying line according to a grouping rule to form a resistor grouping list meeting requirements;
and the sorting and dispatching system controls the sorting robot to sort and group the non-group resistance cards on the conveying line according to the group list.
In one specific embodiment, the grouping rule includes: the single group of the resistor pieces comprises the number S of the resistor pieces and the sum S of the U1mA corresponding to each resistor piece in the single group of the resistor pieces u1ma The number of the resistor pieces included in each group of resistor pieces is less than or equal to S;
the intelligent grouping of the resistance cards which are not grouped according to the grouping rule is carried out to form a resistance card grouping list meeting the requirements, and the intelligent grouping method comprises the following steps:
step S1, when new code spraying information is detected to be put in storage, counting the number N of unassigned resistor discs in a database;
step S2, if the number N of the unassigned resistor sheets is greater than or equal to the number S of the single set of resistor sheets in the pairing rules, ordering the unassigned resistor sheets according to U1mA, selecting S unassigned resistor sheets from the N unassigned resistor sheets according to the ordering, and calculating the sum T of S U1mA corresponding to the S unassigned resistor sheets u1ma When T u1ma Closest to S u1ma When the selected S unassigned resistor sheets are marked as a combination G;
step S2, replacing at least one resistor in the combination G by the resistor outside the combination G based on a preset replacement principle to obtain a replaced combination G, wherein the preset replacement principle is as follows: each resistor sheet in the combination g satisfies the following expression H: s is S u1ma х(1-D) <＝ T u1ma <＝S u1ma *(1+D)；
Step S3, if the sum of residual voltages of the resistor sheets in the combination g is smaller than the upper limit C of residual voltages in the matching rule max Judging that the group matching is successful, marking each resistor sheet state in the combination g as the matched group, and adding 1 to the group code;
step S4, if the sum of residual voltages of the resistor sheets in the combination g is more than or equal to the upper residual voltage limit C max Judging that the grouping fails;
step S5, if the expression H cannot be satisfied, and T u1ma <S u1ma * (1-D) determining that the pairing fails;
step S6, if the expression H cannot be satisfied, and T u1ma >S u1ma * (1+d) reducing the number of the single group of resistor sheets S to make s=s-1, and repeating the steps S2 to S6;
and S7, if the matching fails, waiting for the next new resistor disc to be put in storage, and then carrying out the steps S1 to S7.
In one embodiment, the method further comprises:
step S8, if the grouping is successful, when the grouping has been formed, the number N of groups grp Less than the sorting robot number O, N grp <O, the identification B of the single group is obtained i Marked as 1, otherwise single group is identified as B i Is 0;
the step S2 is preceded by the following step S9:
if single group is configured with group identification B i When the number N of the unassigned resistive patches is greater than or equal to the sorting robot number O multiplied by the number S of the single-set resistive patches, namely N>When=o×s, determining to perform grouping; if B is i When the number N of the unassigned resistor is greater than or equal to the number S of the single-group resistor, namely N>When S, determining to perform grouping; when it is determined to perform grouping, step S2 is performed.
In a specific embodiment, the lightning arrester resistor disc sorting apparatus further comprises sorting vision apparatus for identifying resistor discs located in a sorting vision area;
the sorting robot is controlled to sort and group the unassigned resistor sheets on the conveying line according to the grouping list, and the sorting robot comprises the following steps:
step S01, when the resistor sheets on the conveying line pass through the sorting vision area, the sorting vision equipment identifies code spraying information of the resistor sheets in the sorting vision area and transmits the identified code spraying information to the central control system;
Step S02, the central control system searches a database for a resistor sheet consistent with the code spraying information received from the sorting vision equipment;
step S03, if the central control system does not find the resistor sheet consistent with the code spraying information received from the sorting vision equipment, judging that the code spraying information of the resistor sheet is wrong in recognition, sending a command of grabbing to a rotary line to the sorting robot, and after a specific time, sending a rotary line inflow command by the central control system to enable the resistor sheet with wrong recognition to reenter the sorting vision area for recognition;
and step S04, if the resistor disc consistent with the code spraying information received from the sorting vision equipment is found, the state of the resistor disc is the matched group, the group code corresponding to the found resistor disc is the current sorting output group, the central control system issues an instruction for grabbing the resistor disc to a tray and sorting position coordinates to the sorting robot, and the state of the resistor disc is marked as sorted after the sorting robot finishes grabbing.
In one embodiment, the method further comprises the steps of:
step S05, if a resistor piece consistent with the code spraying information received from the sorting vision equipment is found, the state of the resistor piece is unmatched, the unmatched number in a rotary line is larger than the upper limit of the capacity of the rotary line, a cleaning instruction and a cleaning position coordinate are issued to the sorting robot by the central control system, the state of the resistor piece is marked as cleaned by the central control system after the cleaning action of the sorting robot is completed, and the unmatched number in the rotary line is reduced by 1;
Step S06, if a resistor piece consistent with the code spraying information received from the sorting vision equipment is found, and the state of the found resistor piece is unassigned, but the unassigned number in a revolving line does not reach the upper limit of the capacity of the revolving line, the central control system issues a command of grabbing to the revolving line to the sorting robot, marks that the state of the resistor piece is revolved, and if the resistor piece does not revolve before, adds 1 to the unassigned number in the revolving line;
step S07, if a resistor sheet consistent with the code spraying information received from the sorting vision equipment is found, and the found resistor sheet is the condition except the steps S05 and S06, the central control system issues a command of grabbing to a turning line to the appointed robot, and the state of the resistor sheet is marked as turned;
step S08, when the resistor sheets on the trays of the arrester resistor sheet grouping equipment are placed for one row, according to the advancing distance configured in the grouping rule, the central control system issues a tray advancing instruction to the PLC equipment of the sorting vision equipment until the trays are full, automatically triggering the tray replacement, and issuing a sorting result to the printer and the RFID system for output by the central control system;
and S09, triggering the tail tray matching in each tray when the time interval between the resistor disc passing through the sorting visual area and the last resistor disc passing through the identification visual area is larger than a specific time, namely, judging that no new resistor disc is input.
In one embodiment, the method further comprises the steps of:
step S001, when the resistor sheets pass through the sorting vision area, the central control system increases the number of the resistor sheets passing through the sorting vision area by 1, and counts the number C of the resistor sheets passing through the sorting vision area out And the number of sorted resistance C cur ；
Step S002, the central control system searches the database for the maximum coding interval V of the two continuous resistance sheets of the current sorting group, if the difference between the number of resistance sheets passing through the sorting vision area and the number of sorted resistance sheets is greater than the maximum coding interval V of the two continuous resistance sheets of the current sorting group plus the grouping number S, namely C out -C cur >V+S, judging that manual intervention is needed, and executing step S003;
step S003, the central control system issues a pause instruction to the PLC of the sorting vision equipment, searches the residual resistance sheets to be sorted of the current sorting group in the database, and displays detailed information and corresponding tray information, so that the resistance sheets are manually searched according to the prompt information and placed in the corresponding tray;
step S004, when the fact that the resistor disc is manually placed into the corresponding tray according to the prompt information is monitored, the central control system marks that the resistor disc is sorted, and sends a starting instruction to the PLC.
In a specific embodiment, the central control system is further used for determining position coordinates of a grabbing point of the resistor disc, position coordinates of a cleaning point of the resistor disc, position coordinates of a rotating point of the resistor disc, position coordinates of a placing point on a tray when the resistor disc is sorted and output, the number of the resistor discs which can be contained most and are not matched with each other on the rotating line body, the advancing distance of the conveying line after each row of the resistor discs are placed, and receiving and issuing communication instructions.
As a specific implementation manner: as shown in fig. 1 to 6, the automatic grouping method for the lightning arrester resistor disc provided in the embodiment of the application includes: the system comprises a central control system 1, an identification and warehousing system 2, an intelligent grouping system 3, a sorting and scheduling system 4 and a manual intervention system 5.
As shown in fig. 1 and 2, the central control system 1 is used for configuring relevant parameters and receiving and transmitting communication instructions in the resistor sheet assembling and sorting process. Configuring the model of the resistor disc as XH06; the rejection rule of the unqualified resistor disc is as follows: u1mA is less than 6.05 or residual voltage is more than 15; the resistor matching rule is 24 single-piece, the sum 155 of U1mA, the configuration deviation +/-1%, and the residual voltage upper limit 268; the number of unmatched resistor discs which can be contained at most on the rotary wire body is 20; the advancing distance is 9cm after the resistor disc is placed; the number of the sorting robots is 2; as well as other configuration information.
As shown in fig. 1, 2 and 3, the identifying and warehousing system 2 is used for identifying the code spraying information of the resistor disc on the conveying line, warehousing and archiving, and warning and rejecting the unqualified resistor disc. The central control system 1 establishes communication connection with the recognition visual equipment and the PLC equipment, the resistor on the conveying line triggers visual recognition through the recognition area, the industrial vision transmits the recognized resistor code spraying information to the central control system 1, the central control system 1 writes the code spraying information into a database for archiving, if the resistor U1mA is smaller than 6.05 or residual voltage is larger than 15, the central control system 1 issues a rejection instruction to the PLC, the PLC performs rejection, the state of the resistor is identified as being rejected, and if the resistor is not in accordance with the rejection rule, the identification state is not matched with the group.
As shown in fig. 1 and 4, the intelligent grouping system 3 is used for intelligent grouping of qualified resistance cards on a conveying line. The method comprises the following steps:
s1, counting the number of unassigned resistor pieces in a database when new resistor pieces are put in storage, and if a single-assembled resistor piece is identified as B i When the number of the resistance sheets which are not matched with the sorting robot is larger than or equal to 0 and the number of the resistance sheets which are not matched with the sorting robot is multiplied by the number of the resistance sheets of a single group, namely, when the number of the resistance sheets which are not matched with the sorting robot is larger than or equal to 48, matching is carried out; if B is i And when the number of the resistance sheets which are not assembled is equal to or greater than 24, assembling.
S2, if the number of the unassigned resistor is greater than or equal to 24, ordering the unassigned resistor according to U1mA,
the combination of resistors with a continuous length of 24 was calculated to bring the sum of the resistors U1mA of the combination closest to 155.
S3, replacing the resistor combination and the combined external resistor so that the sum of the U1mA of the resistor combination is larger than or equal to 153.45 and smaller than or equal to 156.55, if the condition is met and the sum of residual voltages of the resistors in the combination is smaller than 268, successful grouping is achieved, the state of the resistors in the combination is marked as the matched group, the group code is 1, and then repeating the steps S2 to S3; if the condition is met but the sum of residual pressures is greater than or equal to 268, the pairing fails; if the combined resistor sheet U1mA sum is less than 153.45, the pairing fails; if the sum of the combined resistor sheets U1mA is larger than 156.55, the number of the resistor sheets in a single group is reduced, the group is assembled according to 23 groups, and the steps S2 to S3 are repeated.
S4, if the matching is successful, when the number of the matched groups is smaller than 2, modifying the single matched group identifier B i 1, otherwise modify single set group identification B i Is 0; and if the group allocation fails, waiting for the next new resistor disc to be put in storage and then carrying out S1 to S4.
As shown in fig. 1, 2, 4 and 5, the sorting and dispatching system 4 is used for sorting and dispatching the resistor sheets on the conveying line. The method comprises the following steps:
S1, the resistor disc on the conveying line passes through a sorting vision area, and sorting vision transmits the identified resistor disc code spraying information to the central control system 1.
S2, the central control system 1 searches a resistor sheet consistent with the code spraying information in a database, if the resistor sheet is not found, the code spraying information of the resistor sheet is identified incorrectly, the central control system 1 issues a command of grabbing to a rotary line to a specified robot, and after 30 seconds, the central control system 1 issues a command of flowing in the rotary line to enable the resistor sheet with the identification incorrectly to enter sorting vision again for identification; if the resistor disc meeting the conditions is found, the state of the resistor disc is the matched group, the corresponding group is coded into the current group to be sorted, the central control system 1 issues a command of grabbing to a tray to the appointed robot, and the state of the resistor disc is marked to be sorted after grabbing is completed; if the resistor sheet meeting the conditions is found, the state of the resistor sheet is unmatched, the unmatched number in the revolving line is larger than 20, the central control system 1 issues a cleaning instruction to the appointed robot, the state of the resistor sheet is marked to be cleaned after the cleaning action is completed, and the unmatched number in the revolving line is reduced by 1; if the state of the resistor is unassigned, but the unassigned number in the revolving line is less than or equal to 20, the central control system 1 issues a command for grabbing the revolving line to the appointed robot, marks that the state of the resistor is revolved, and if the resistor is not revolved before, the unassigned number in the revolving line is added with 1; in other cases, the central control system 1 issues a command of grabbing to a turning line to the appointed robot, and marks the state of the resistor disc as turned.
And S3, when the resistor sheets on the tray are placed in one row, the central control system 1 issues the tray to the PLC equipment to advance for 9cm until the tray is full of the resistor sheets to automatically trigger the replacement of the tray, and the central control system 1 issues the sorting result to the printer and the RFID system to output.
S4, when the time interval between the time of sorting the visual area resistor disc and the time of the last passing identification visual resistor disc is more than 3 minutes, indicating that no new material enters, counting the number of unassigned resistor discs in the database, and if the number of unassigned resistor discs is more than 24, performing assembly.
As shown in fig. 1, 2, 5 and 6, the manual intervention system 5 is used for performing manual intervention when individual resistor sheets are subjected to multiple recognition errors under sorting vision, and sorting efficiency is affected. The method comprises the following steps:
s1, counting the number of the resistance sheets passing through sorting vision and the number of the sorted resistance sheets when the resistance sheets pass through the sorting vision area, searching the maximum coding interval of two continuous resistance sheets of the current sorting group in a database by the central control system 1, and judging that manual intervention is needed if the difference between the number of the resistance sheets passing through sorting vision and the number of the sorted resistance sheets is greater than the maximum coding interval of two continuous resistance sheets of the current sorting group plus 24.
S2, the central control system 1 issues a pause instruction to the PLC, searches the remaining resistance sheets to be sorted of the current sorting group in the database, and displays detailed information and corresponding tray information.
S3, manually searching the resistor disc according to the prompt information, putting the resistor disc into a corresponding tray, marking the state of the resistor disc as sorted by the central control system 1, and sending a starting instruction to the PLC.
S4, sorting out the resistor pieces, and increasing the number of the sorted out resistor pieces by 1.
The foregoing is merely a specific embodiment of the present application, but the protection scope of the present application is not limited thereto, and any person skilled in the art can easily think about changes or substitutions within the technical scope of the present application, and the changes and substitutions are intended to be covered in the protection scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.
Claims (6)
1. An automatic grouping and sorting method for lightning arrester resistor sheets, characterized in that the method is applied to an automatic grouping system for lightning arrester resistor sheets, the automatic grouping system for lightning arrester resistor sheets comprises a central control system, a recognition warehouse system, an intelligent grouping system and a sorting and dispatching system, the method is used for controlling the automatic grouping and sorting equipment for lightning arrester resistor sheets so that the automatic grouping and sorting equipment for lightning arrester resistor sheets can automatically group the resistor sheets to be grouped, the automatic grouping and sorting equipment for lightning arrester resistor sheets comprises a conveying line for conveying the resistor sheets and a sorting robot for operating the resistor sheets, and the method comprises the following steps:
The identification warehousing system identifies code spraying information of the resistor disc to be assembled on the conveying line and sends the code spraying information to the central control system;
the central control system stores the code spraying information in a warehouse, determines the parameter information of the resistor disc to be assembled according to the code spraying information, and determines whether the resistor disc to be assembled is qualified according to the parameter information;
when the central control system judges that the resistor sheets to be assembled are unqualified, the rejecting equipment is controlled to reject the resistor sheets to be assembled, the resistor sheets to be assembled are marked as rejected resistor sheets, when the resistor sheets to be assembled are judged to be qualified, the resistor sheets to be assembled are marked as non-assembled resistor sheets, and statistics is carried out on the non-assembled resistor sheets;
the intelligent grouping system intelligently groups each unassigned resistor on the conveying line according to a grouping rule to form a resistor grouping list meeting requirements;
the sorting and dispatching system controls the sorting robot to sort and group the non-group resistance cards on the conveying line according to the group list;
the grouping rule comprises: the single group of the resistor pieces comprises the number S of the resistor pieces and the sum S of the U1mA corresponding to each resistor piece in the single group of the resistor pieces u1ma The number of the resistor pieces included in each group of resistor pieces is less than or equal to S;
each unassigned resistor is intelligently assembled according to an assembling rule to form a resistor assembling list meeting requirements, and the method comprises the following steps:
step S1, when new code spraying information is detected to be put in storage, counting the number N of unassigned resistor discs in a database;
step S2, if the number N of the unassigned resistor sheets is greater than or equal to the number S of the single set of resistor sheets in the pairing rules, ordering the unassigned resistor sheets according to U1mA, selecting S unassigned resistor sheets from the N unassigned resistor sheets according to the ordering, and calculating the sum T of S U1mA corresponding to the S unassigned resistor sheets u1ma When T u1ma Closest to S u1ma When the selected S unassigned resistor sheets are marked as a combination G;
step S2, replacing at least one resistor in the combination G by the resistor outside the combination G based on a preset replacement principle to obtain a replaced combination G, wherein the preset replacement principle is as follows: each resistor sheet in the combination g satisfies the following expression H: s is S u1ma х(1-D) <＝ T u1ma <＝S u1ma * (1+D), D is the pairing bias;
step S3, if the sum of residual voltages of the resistor sheets in the combination g is smaller than the upper limit C of residual voltages in the matching rule max Judging that the group matching is successful, marking each resistor sheet state in the combination g as the matched group, and adding 1 to the group code;
Step S4, if the sum of residual voltages of the resistor sheets in the combination g is more than or equal to the upper residual voltage limit C max Judging that the grouping fails;
step S5, if the expression H cannot be satisfied, and T u1ma <S u1ma * (1-D) determining that the pairing fails;
step S6, if the expression H cannot be satisfied, and T u1ma >S u1ma * (1+d) reducing the number of the single group of resistor sheets S to make s=s-1, and repeating the steps S2 to S6;
and S7, if the matching fails, waiting for the next new resistor disc to be put in storage, and then carrying out the steps S1 to S7.
2. The method according to claim 1, wherein the method further comprises:
step S8, if the grouping is successful, when the grouping has been formed, the number N of groups grp Less than the sorting robot number O, N grp <O, the identification B of the single group is obtained i Marked as 1, otherwise single group is identified as B i Is 0;
the step S2 is preceded by the following step S9:
if single group is configured with group identification B i When the number N of the unassigned resistive patches is greater than or equal to the sorting robot number O multiplied by the number S of the single-set resistive patches, namely N>When=o×s, determining to perform grouping; if B is i When the number N of the unassigned resistor is greater than or equal to the number S of the single-group resistor, namely N>When S, determining to perform grouping; when it is determined to perform grouping, step S2 is performed.
3. The method of claim 1, wherein the arrester resistor sheet allocation grouping apparatus further includes a sort vision apparatus for identifying the resistor sheets located in the sort vision area;
the sorting robot is controlled to sort and group the unassigned resistor sheets on the conveying line according to the grouping list, and the sorting robot comprises the following steps:
step S01, when the resistor sheets on the conveying line pass through the sorting vision area, the sorting vision equipment identifies code spraying information of the resistor sheets in the sorting vision area and transmits the identified code spraying information to the central control system;
step S02, the central control system searches a database for a resistor sheet consistent with the code spraying information received from the sorting vision equipment;
step S03, if the central control system does not find the resistor sheet consistent with the code spraying information received from the sorting vision equipment, judging that the code spraying information of the resistor sheet is wrong in recognition, sending a command of grabbing to a rotary line to the sorting robot, and after a specific time, sending a rotary line inflow command by the central control system to enable the resistor sheet with wrong recognition to reenter the sorting vision area for recognition;
And step S04, if the resistor disc consistent with the code spraying information received from the sorting vision equipment is found, the state of the resistor disc is the matched group, the group code corresponding to the found resistor disc is the current sorting output group, the central control system issues an instruction for grabbing the resistor disc to a tray and sorting position coordinates to the sorting robot, and the state of the resistor disc is marked as sorted after the sorting robot finishes grabbing.
4. A method according to claim 3, characterized in that the method further comprises the steps of:
step S05, if a resistor piece consistent with the code spraying information received from the sorting vision equipment is found, the state of the resistor piece is unmatched, the unmatched number in a rotary line is larger than the upper limit of the capacity of the rotary line, a cleaning instruction and a cleaning position coordinate are issued to the sorting robot by the central control system, the state of the resistor piece is marked as cleaned by the central control system after the cleaning action of the sorting robot is completed, and the unmatched number in the rotary line is reduced by 1;
step S06, if a resistor piece consistent with the code spraying information received from the sorting vision equipment is found, and the state of the found resistor piece is unassigned, but the unassigned number in a revolving line does not reach the upper limit of the capacity of the revolving line, the central control system issues a command of grabbing to the revolving line to the sorting robot, marks that the state of the resistor piece is revolved, and if the resistor piece does not revolve before, adds 1 to the unassigned number in the revolving line;
Step S07, if a resistor sheet consistent with the code spraying information received from the sorting vision equipment is found, and the found resistor sheet is the condition except the steps S05 and S06, the central control system issues a command of grabbing to a turning line to the appointed robot, and the state of the resistor sheet is marked as turned;
step S08, when the resistor sheets on the trays of the arrester resistor sheet grouping equipment are placed for one row, according to the advancing distance configured in the grouping rule, the central control system issues a tray advancing instruction to the PLC equipment of the sorting vision equipment until the trays are full, automatically triggering the tray replacement, and issuing a sorting result to the printer and the RFID system for output by the central control system;
and S09, triggering the tail tray matching in each tray when the time interval between the resistor disc passing through the sorting visual area and the last resistor disc passing through the identification visual area is larger than a specific time, namely, judging that no new resistor disc is input.
5. The method according to claim 4, further comprising the step of:
step S001, when the resistor sheets pass through the sorting vision area, the central control system increases the number of the resistor sheets passing through the sorting vision area by 1, and counts the number C of the resistor sheets passing through the sorting vision area out And the number of sorted resistance C cur ；
Step S002, the central control system searches the database for the maximum coding interval V of the two continuous resistance sheets of the current sorting group, if the difference between the number of resistance sheets passing through the sorting vision area and the number of sorted resistance sheets is greater than the maximum coding interval V of the two continuous resistance sheets of the current sorting group plus the grouping number SC, i.e out -C cur >V+S, judging that manual intervention is needed, and executing step S003;
step S003, the central control system issues a pause instruction to the PLC of the sorting vision equipment, searches the residual resistance sheets to be sorted of the current sorting group in the database, and displays detailed information and corresponding tray information, so that the resistance sheets are manually searched according to the prompt information and placed in the corresponding tray;
step S004, when the fact that the resistor disc is manually placed into the corresponding tray according to the prompt information is monitored, the central control system marks that the resistor disc is sorted, and sends a starting instruction to the PLC.
6. The method of claim 5, wherein the central control system is further configured to determine a position coordinate of a resistor capturing point, a position coordinate of a resistor cleaning point, a position coordinate of a resistor turning point, a position coordinate of a placement point on a tray when the resistor is sorted out and output, a number of unassigned resistors which can be most accommodated on a turning line body, a forward distance of a conveyor line after each row of resistors is placed, and receiving and issuing a communication command.
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