CN114377971A - Detection control method for balance wheel sorting stall - Google Patents
Detection control method for balance wheel sorting stall Download PDFInfo
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- CN114377971A CN114377971A CN202111645687.0A CN202111645687A CN114377971A CN 114377971 A CN114377971 A CN 114377971A CN 202111645687 A CN202111645687 A CN 202111645687A CN 114377971 A CN114377971 A CN 114377971A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C3/00—Sorting according to destination
- B07C3/02—Apparatus characterised by the means used for distribution
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The balance wheel sorting stall detection control method provided by the invention combines a relative positioning mode between a tracking area and a sorting grid and an absolute positioning mode of the whole sorting conveying line, so as to achieve the design purposes of controlling the following error of the parcel spacing within an industry reference parameter, improving the accuracy and fault tolerance of sorting operation and improving the success rate of sorting operation. Adding a position information interface to each imported package in a data stack form in a PLC master control system, and synchronously sharing and updating data in the stack in the process of implementing position information tracking; setting area detection in front of the sorting grid to determine whether the packages appear at the designated positions in the detection area according to the designated time, wherein the position detection of package conveying is executed according to the pre-adaptive learning result; if the following position error exceeds the set range, determining that stall occurs and quantizing a specific error value; based on the actual error value, the forward feed speed is adjusted by the wobbler assembly to eliminate the actual following error.
Description
Technical Field
The invention relates to a detection and control method for a special-shaped piece in a stalling state in sorting and conveying, and belongs to the field of logistics sorting.
Background
Along with the rapid development of the E-commerce logistics and the automatic conveying technology, the package sorting and conveying speed and efficiency are obviously improved. At present, balance wheel sorting machines are generally adopted in logistics transfer fields as main sorting and conveying equipment, balance wheel modules serving as execution mechanisms have multiple actions of starting and stopping, clockwise and anticlockwise swinging, centering and returning to zero and the like according to different sorting modes, meanwhile, a PLC serves as a main control to control a servo driver through a PR mode, EtherCAT or pulse and other modes so as to execute different swinging instructions, and sorting objects are searched in a package queue and sorting actions are executed.
Some types of packages, such as thin, small or shaped (spherical) bags, are prone to stalling due to uneven surfaces, low friction or uneven distribution, i.e. the package arrives at the balance module later than the estimated time of the tracking algorithm. Because the existing balance wheel only receives and executes the instruction of the master control system in a unidirectional mode, the problem that packages cannot be sorted or are sorted wrongly exists after stalling occurs in the conveying process, and the accuracy and the efficiency of the whole sorting operation are directly influenced.
The conventional balance wheel sorting machine adopts an open loop tracking algorithm in an absolute mode, namely, during self-adaptive learning, an interval measurement and calculation of each crossing from the starting end to the tail end of a sorting conveying line is established, so that the time point of the arrival of the package in operation is recorded and stored, and the time point is used as a tracking comparison reference value when the package is identified to form a queue for conveying. After the parcels are identified to form a traveling queue, the PLC master control system records each parcel in the queue, compares the reference time set by the system, and controls the balance wheel to execute the designated sorting action according to the set time point by combining the serial number and the interval of the queue. Based on the open-loop tracking mode, only the difference between the parcel in the tracking process and the preset reference value can be calculated, the adaptive change cannot be made under the condition of stall, the blindness of the sorting action is large, and coping and solving means are lacked.
In view of this, the present patent application is specifically proposed.
Disclosure of Invention
The balance wheel sorting stall detection control method provided by the invention is used for solving the problems in the prior art, and adopts a relative positioning mode between a tracking area and a sorting grid and an absolute positioning mode of the whole sorting conveying line in a combined mode, so that the design purposes of controlling the following error of the parcel spacing within an industry reference parameter, improving the sorting operation accuracy and fault tolerance and improving the sorting operation power are achieved.
In order to achieve the design purpose, the balance wheel sorting stall detection control method is characterized in that a position information interface is added to each introduced package in a PLC master control system in a data stack mode, and data in the stack are synchronously shared and updated in the process of implementing position information tracking; after the packages are guided into the balance wheel sorting machine, integrally caching the physical attributes and sorting instruction information of the packages into a master database; position tracking between the balance wheel sorting machines only transmits position information and a system retrieval number, and a sorting instruction can be obtained through the system retrieval number to stop so as to judge whether the sorting instruction belongs to a current sorting grid; setting area detection in front of the sorting grid to determine whether the packages appear at the designated positions in the detection area according to the designated time, wherein the position detection of package conveying is executed according to the pre-adaptive learning result; if the following position error exceeds the set range, determining that stall occurs and quantizing a specific error value; based on the actual error value, the forward feed speed is adjusted by the wobbler assembly to eliminate the actual following error.
Further, the balance wheel sorting stall detection control method comprises the following implementation steps:
1) the self-adaptive learning method is characterized in that the self-adaptive learning method,
setting initial detection photoelectric signals and real-time position trigger photoelectric signals in front of each sorting cell according to the total length of the balance wheel sorting machine and the layout of the sorting cells;
establishing a data stack of the parcel position information in the PLC master control system, and executing a parcel position tracking algorithm;
learning and storing the arrival time data and the position detection result before each sorting grid, and setting a time node for triggering photoelectric opening and a starting verification judgment boundary line for position detection;
the method comprises the following steps of performing multiple learning by using packages of different specifications and types, recording and storing the stall condition and the following error data range of each package after the packages are guided into a balance wheel sorting machine, and finally determining the maximum pull distance range of a balance wheel module;
2) the stall detection is carried out in such a way that,
initializing a PLC master control system and a master database;
executing a time tracking algorithm after package import;
at the preset arrival time node, starting check judgment by triggering photoelectricity in front of the sorting grid, and detecting and judging whether the package is in the check judgment range; if so, the package is not stalled, and then the execution action of the balance wheel module is determined according to the system retrieval number; if the parcel part is in the starting check judgment, quantifying a following error value between the actual position of the parcel and a set value in the starting check judgment;
the detection result and the determined following error value data are uploaded to a PLC master control system to update a master database and a data stack,
3) the distance between the two ends of the pull rod is adjusted,
adjusting the conveying speed of the balance wheel module according to the following error value, and realizing the pull distance of the front and back packages until the following error is eliminated;
the packages enter a sorting grid, and sorting or forward conveying action is executed;
and uploading the adjusted parcel position information and the front-back distance data to a PLC master control system so as to update a master database and a data stack.
Further, in the step 2) and the step 3), uploading of information data with the PLC master control system is performed based on the Profinet communication protocol, and a package stall interface is reserved in the uploaded GSD file.
Further, in the step 3), when the balance wheel is triggered to trigger the photoelectric device, a difference value between a package tracking time sequence preset by the master control system and an actual photoelectric triggering time sequence is calculated, the difference value is uploaded to the PLC master control system to update the master database and serve as a reference for subsequent distance adjustment, and a corresponding relationship between the time sequence difference value and the following error value and the distance adjustment value is established.
Further, in the step 3), in the balance sorting machine conveying part in front of the sorting grid, the balance modules are distributed in rows and columns, and each balance module is controlled by a single connecting driver; and calculating the logic time sequence and interval time of sequential speed change along the conveying direction according to the following error value and the time sequence difference value of triggering photoelectricity so as to sequentially adjust the speeds of the multiple sets of balance wheel modules at the same speed and in the same direction.
In summary, the balance wheel sorting stall detection control method has the advantages that the regional detection is added before the packages enter the designated sorting grid so as to determine whether the packages stall or not, the interval accumulated errors among the packages can be eliminated in a targeted manner, the distance pulling action is executed in a supplementing manner, the dynamic adjustment of the distance and the relative position of the front packages and the back packages is carried out, and meanwhile, the adjusted package position and interval information is uploaded to a main control system so as to correct tracking data, so that the problem that the packages cannot be sorted or are sorted incorrectly due to stall can be fundamentally solved, and the sorting accuracy and the operation efficiency are effectively improved.
Drawings
The present application is now further described with reference to the following drawings;
FIG. 1 is a schematic diagram of a master control system data architecture in accordance with the present application;
FIG. 2 is a distribution diagram of detection zones at an adaptive learning bin based on the present application;
fig. 3 is a diagram of a balance sorting layout according to the present application.
Detailed Description
To further illustrate the technical solutions adopted by the present application to achieve the intended design objectives, the following preferred embodiments are provided in conjunction with the accompanying drawings.
In the following description, specific details are set forth in order to provide a thorough understanding of the present application. This application is capable of embodiments in many different forms than those described herein and it is capable of similar extensions by those skilled in the art without departing from the spirit and scope of this application. The application is therefore not limited to the particular embodiments disclosed below.
In embodiment 1, as shown in fig. 1, the balance sorting stall detection control method according to the present application adds a position information interface to each introduced package in a data stack form in a PLC master control system, and synchronously shares and updates data in the stack in the process of implementing position information tracking to establish full-flow position tracking of each package, and adjusts a distance between a front package and a rear package based on a result of a tracking algorithm to eliminate a following error between the front package and the rear package caused by stall.
Specifically, after the packages are guided into the balance wheel sorting machine, the physical attributes and sorting instruction information of the packages are integrally cached in a master database; the position tracking between the balance wheel sorting machines only transmits position information and a system retrieval number, and a sorting instruction can be obtained through the system retrieval number to stop so as to judge whether the sorting machine belongs to the current sorting grid or not.
And (3) setting area detection in front of the sorting grid to determine whether the packages appear at the positions appointed by the detection area according to appointed time, executing position detection of package conveying according to a pre-adaptive learning result, and judging that stalling occurs and a specific error value can be quantized if a following position error exceeds the range of an industry reference parameter.
Based on the calculated actual error value, the forward feed speed is adjusted by the balance wheel module to eliminate the actual following error.
And uploading the position information after the stall package pull distance is adjusted to a sorting line main database, and updating data in a stack for a position tracking algorithm of a subsequent package queue.
As shown in fig. 2, a start detection photoelectric device for detecting whether the package enters the tracking area or not is arranged at the leading-in end of the balance wheel sorting line, so as to establish a start end for enabling the package queue to enter the tracking area and tracking the real-time position of each package;
and arranging a balance wheel in front of each sorting grid to trigger photoelectricity so as to execute a checking process of the real-time position state of the package and judge whether a stalling phenomenon occurs or not.
In combination with the above-mentioned photoelectric setting and detecting means, as shown in fig. 1, after the parcel is introduced into the balance wheel sorting machine, the physical attributes (including the external dimension data) and the position in the queue of the parcel should advance into the designated window in front of the sorting cell according to the time node preset by the adaptive learning.
The detection of the start check judgment is executed by triggering photoelectricity by the balance wheel in fig. 2, and the size of the tracking area is determined according to the external dimension of the package;
if the package is within the predetermined area, indicating that the package is not stalled, the subsequent balance module is not required to perform a compensating distance adjustment, such as if the package enters a sorting gate.
And when entering the current sorting grid, selecting to convey forwards or execute a swing sorting instruction according to a system retrieval number given by the PLC master control system.
If the actual position of the package is already in a partially out of the predetermined zone, indicating a stall problem, a transport speed adjustment for a pull-off adjustment is required according to the control method described herein. Otherwise, sorting failure is easily caused.
If the package has completely left the predetermined area, subsequent sortings are deemed missing targets and cannot be sorted.
Based on the above design points, the balance wheel sorting stall detection control method of the application comprises the following implementation steps:
1) adaptive learning
As shown in fig. 2, the initial detection photoelectric and the real-time position trigger photoelectric before each sorting cell are arranged according to the total length of the balance wheel sorting machine and the layout of the sorting cells;
establishing a data stack of the parcel position information in the PLC master control system, and executing a parcel position tracking algorithm;
learning and storing the arrival time data and the position detection result before each sorting grid, and setting a time node for triggering photoelectric opening and a starting verification judgment boundary line for position detection;
and (3) performing multiple learning by using parcels with different specifications and types, recording and storing the stall condition and the following error data range of each parcel after being introduced into the balance wheel sorting machine, and finally determining the maximum pull distance range of the balance wheel module.
2) Stall detection
Initializing a PLC master control system and a master database;
as in the prior art, a time tracking algorithm after package import is performed;
at the preset arrival time node, starting check judgment by triggering photoelectricity in front of the sorting grid, and detecting and judging whether the package is in the check judgment range; if so, the package is not stalled, and then the execution action of the balance wheel module is determined according to the system retrieval number; if the parcel part is in the starting check judgment, quantifying a following error value between the actual position of the parcel and a set value in the starting check judgment;
and uploading the detection result and the determined following error value data to a PLC master control system so as to update a master database and a data stack.
3) Adjusting the pull distance
Adjusting the conveying speed of the balance wheel module according to the following error value, and realizing the pull distance of the front and back packages until the following error is eliminated;
the packages enter a sorting grid, and sorting or forward conveying action is executed;
and uploading the adjusted parcel position information and the front-back distance data to a PLC master control system so as to update a master database and a data stack.
Further, in the above step 2), when each parcel enters the conveying queue, the position at which the image profile is recognized is set as the length of the queue.
As shown in the table below, each time a photoelectric scan is initiated, the position in the queue decreases, and correspondingly the number of encoder pulses decreases, so that the position of the package is updated in increments synchronized with the conveyance of the balance sorter.
For example, if the queue is 100 pulses long, when the first parcel enters the queue, its position is 100, after 100 encoder pulses, its position is 0;
if a subsequent plurality of parcels enter the queue, then any parcel that enters after the first parcel has a position recorded relative to the previous parcel.
Initially, the first parcel enters the queue from the tail, length (100 pulses).
After the sorter moves 20 encoder pulses, the second parcel enters the queue.
After the sorter has moved 30 encoder pulses again, the third parcel enters the queue and so on.
The package with the sequence number of 1 in the queue has 50 encoder pulses away from the queue head; the parcel with sequence number 2 is 70 pulses from the head of the queue or 20 pulses from the parcel distance with sequence number 1; a parcel with sequence number 3 has 100 pulses from the head of the queue and 30 pulses from the parcel distance with sequence number 2.
In the above parcel queue, the real-time position of the parcel relative to the encoder can be simplified and updated due to the relative position mark of the adjacent parcel spacing. After the encoder increments, only the first parcel at the head of the queue needs to update its real-time position, and the other parcels only update the relative position data.
Therefore, the real-time position information of the packages is uploaded to the PLC master control system at the same time so as to update the master database and the data stack.
In the step 2) and the step 3), uploading of information data with the PLC master control system is executed based on a Profinet communication protocol, and a package stall interface is reserved in an uploaded GSD file so as to receive a tracking error value transmitted by the master control system in real time and realize real-time sharing of package position information.
To avoid the package location condition shown in fig. 2, transitioning to a loss of location tracking condition as shown in fig. 3 results in the package not being sorted. When the parcel triggering balance wheel triggers photoelectricity, the difference value between the parcel tracking time sequence preset by the master control system and the time sequence of actual triggering photoelectricity is calculated to serve as the difference value between the detection results of the time tracking algorithm and the position tracking algorithm, the difference value is uploaded to the PLC master control system to update the master database and serves as the reference basis of subsequent distance adjustment, and the corresponding relation between the time sequence difference value and the following error value and the distance value of the distance adjustment is established, so that the algorithm precision of self-adaptive learning and the accuracy of the distance adjustment are improved simultaneously.
As shown in fig. 3, in step 3) above, a row of distributed balance wheel modules is adopted in the balance wheel sorter conveying section before the sorting cell, and each balance wheel module group is controlled by a separate connecting driver.
And calculating the logic time sequence and interval time of sequential speed change along the conveying direction according to the following error value and the time sequence difference value of triggering photoelectricity so as to sequentially adjust the speeds of the multiple sets of balance wheel modules in the same speed and the same direction, wherein the conveying speed change interval can be set to be 1.5m/s to 2.8m/s, and the requirement of adjusting the pull distance can be met.
Based on this application, balance sorting machine and PLC major control system carry out the dual detection and the data of arrival time, real-time position state simultaneously and pass each other to implement and follow error detection and data quantization before the letter sorting check, avoid the tracking failure because of the stall causes.
In summary, the embodiments shown in the drawings are only preferred embodiments for achieving the objects of the present invention. Those skilled in the art can now appreciate that many other alternative constructions will be apparent which are consistent with the design of this invention. Other structural features thus obtained are also intended to fall within the scope of the solution according to the invention.
Claims (5)
1. A balance wheel sorting stall detection control method is characterized in that: adding a position information interface to each imported package in a data stack form in a PLC master control system, and synchronously sharing and updating data in the stack in the process of implementing position information tracking;
after the packages are guided into the balance wheel sorting machine, integrally caching the physical attributes and sorting instruction information of the packages into a master database; position tracking between the balance wheel sorting machines only transmits position information and a system retrieval number, and sorting instruction information can be obtained through the system retrieval number to judge whether the sorting instruction information belongs to a current sorting grid;
setting area detection in front of the sorting grid to determine whether the packages appear at the designated positions in the detection area according to the designated time, wherein the position detection of package conveying is executed according to the pre-adaptive learning result; if the following position error exceeds the set range, determining that stall occurs and quantizing a specific error value;
based on the actual error value, the forward feed speed is adjusted by the wobbler assembly to eliminate the actual following error.
2. The balance sorting stall detection control method according to claim 1, wherein: comprises the following implementation steps of the following steps of,
1) the self-adaptive learning method is characterized in that the self-adaptive learning method,
setting initial detection photoelectric signals and real-time position trigger photoelectric signals in front of each sorting cell according to the total length of the balance wheel sorting machine and the layout of the sorting cells;
establishing a data stack of the parcel position information in the PLC master control system, and executing a parcel position tracking algorithm;
learning and storing the arrival time data and the position detection result before each sorting grid, and setting a time node for triggering photoelectric opening and a starting verification judgment boundary line for position detection;
the method comprises the following steps of performing multiple learning by using packages of different specifications and types, recording and storing the stall condition and the following error data range of each package after the packages are guided into a balance wheel sorting machine, and finally determining the maximum pull distance range of a balance wheel module;
2) the stall detection is carried out in such a way that,
initializing a PLC master control system and a master database;
executing a time tracking algorithm after package import;
at a preset arrival time node, starting verification judgment by triggering photoelectric opening in front of a sorting grid, and detecting and judging whether the package is in a verification judgment range or not; if so, the package is not stalled, and then the execution action of the balance wheel module is determined according to the system retrieval number; if the parcel part is in the check judgment, quantifying a following error value between the actual position of the parcel and a set value in the start check judgment;
the detection result and the determined following error value data are uploaded to a PLC master control system to update a master database and a data stack,
3) the distance between the two ends of the pull rod is adjusted,
adjusting the conveying speed of the balance wheel module according to the following error value, and realizing the pull distance of the front and back packages until the following error is eliminated;
the packages enter a sorting grid, and sorting or forward conveying action is executed;
and uploading the adjusted parcel position information and the front-back distance data to a PLC master control system so as to update a master database and a data stack.
3. The balance sorting stall detection control method according to claim 2, wherein: in the step 2) and the step 3), uploading of information data with the PLC master control system is executed based on a Profinet communication protocol, and a package stall interface is reserved in an uploaded GSD file.
4. The balance sorting stall detection control method according to claim 3, wherein: in the step 3), when the parcel triggering balance wheel triggers the photoelectricity, a difference value between a parcel tracking time sequence preset by the master control system and an actual photoelectric triggering time sequence is calculated, the difference value is uploaded to the PLC master control system to update a master database and serve as a reference basis for subsequent distance adjustment, and a corresponding relation between the time sequence difference value and a following error value and a distance value for distance adjustment is established.
5. The balance sorting stall detection control method according to claim 4, wherein: in the step 3), in the balance wheel sorting machine conveying part in front of the sorting grid, the balance wheel modules are distributed in a row and column mode, and each balance wheel module is controlled by a single connecting driver;
and calculating the logic time sequence and interval time of sequential speed change along the conveying direction according to the following error value and the time sequence difference value of triggering photoelectricity so as to sequentially adjust the speeds of the multiple sets of balance wheel modules at the same speed and in the same direction.
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