CN117840050B - Logistics package separation coupling and full-automatic packing method and device - Google Patents

Logistics package separation coupling and full-automatic packing method and device Download PDF

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Publication number
CN117840050B
CN117840050B CN202410251699.2A CN202410251699A CN117840050B CN 117840050 B CN117840050 B CN 117840050B CN 202410251699 A CN202410251699 A CN 202410251699A CN 117840050 B CN117840050 B CN 117840050B
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package
coupling
packages
speed
target
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CN117840050A (en
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张承业
鞠世林
楼星星
徐俊康
徐美金
孙高
吴飞其
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Hangzhou Confirmware Technology Co ltd
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Hangzhou Confirmware Technology Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
    • B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
    • B07C3/00—Sorting according to destination
    • B07C3/10—Apparatus characterised by the means used for detection ofthe destination
    • B07C3/14—Apparatus characterised by the means used for detection ofthe destination using light-responsive detecting means
    • 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
    • B07C3/08—Apparatus characterised by the means used for distribution using arrangements of conveyors

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Abstract

The invention discloses a logistics package separation coupling and full-automatic packing method and device; the automatic packaging device comprises a separating coupler and a precise coupling conveying mechanism which are connected in sequence. The split coupler includes a camera and a plurality of coupling units. And a light curtain sensor is arranged at the joint of the separation coupler and the accurate coupling conveying mechanism. According to the invention, the parcels which are tiled and input are output one by one through the separating coupler, and the speed of the parcels is dynamically adjusted by matching with the images acquired by the camera, so that the parcel core point is preliminarily coupled with the center point of the target trolley on the sorting machine on the separating coupler, and the rhythm of the parcel output by the separating coupler is matched with the operation rhythm of the sorting machine. In addition, the invention introduces a precise coupling conveying mechanism behind the separation coupler; the accurate coupling conveying mechanism can further regulate and control the time when the packages arrive at the sorting machine by controlling the conveying speed of the packages which are input one by one, so that the coupling deviation between the packages and the sorting machine is reduced.

Description

Logistics package separation coupling and full-automatic packing method and device
Technical Field
The invention belongs to the technical field of logistics sorting, and particularly relates to a logistics package separation coupling and full-automatic packing method and device.
Background
At present, in the field of various express delivery, manual goods-of-furniture are required to be packed in front of a straight-line crossed belt sorting machine, and workers are required to place packages on a sorting trolley; the sorting trolley passes through the scanning area and then determines a target grid port; in order to ensure efficiency, the running speed of the straight-line crossed belt sorting machine is about 1.5m/s, and long-time goods placing can lead to fatigue of personnel, so that goods placing can be disordered and wrong parts are generated. Meanwhile, a straight-line crossed belt sorting machine is generally required to be provided with four pieces of goods-arranging personnel, so that the logistics sorting cost is greatly increased. In addition, the manual packing scheme of the linear sorting machine is a scheme of packing first and then scanning, so that a scanning area needs to be arranged in the sorting machine, and the number of the allowed arranged grids is reduced.
Disclosure of Invention
The invention aims to provide a logistics package separation coupling and full-automatic packing method and device.
In a first aspect, the invention provides a logistics package separation coupling and full-automatic packing method, which adopts an automatic packing system to comprise a separation coupler and an accurate coupling conveying mechanism which are sequentially connected. The split coupler includes a plurality of coupling units arranged in a matrix, and a camera capable of photographing each of the coupling units. Each coupling unit adopts an independently controlled conveyer belt structure. And a light curtain sensor is arranged at the joint of the separation coupler and the accurate coupling conveying mechanism.
The logistics package separation coupling and full-automatic packing method comprises the following steps:
step one, conveying the package to a separation coupler.
And step two, collecting package data. The camera performs periodic image acquisition on the separation coupler; and after each image acquisition, extracting the outline and the core point position of each package in the obtained image, and re-executing the third and fourth steps.
And thirdly, dividing all packages on the separation coupler into unprocessed packages and separated packages. According to the positions and the outlines of the packages, the unprocessed packages are converted into separated packages one by one, so that the conveying control of each separated package can not influence the conveying speed of all the unprocessed packages.
Step four, sorting trolleys serving as target trolleys are respectively selected for the separated packages, and theoretical coupling speeds v c of the separated packages are respectively calculated; the theoretical coupling speed v c satisfies the following condition: the length of time that the core point of the separated package is conveyed to the stop boundary line of the separation coupler at the theoretical coupling speed v c is equal to the length of time that the center point of the corresponding target trolley runs to the first target coupling position of the preset sorting machine. The length of time required for the package to be transported from the separation coupler from the termination boundary line to the wrapping position of the sorter at the preset wrapping speed is equal to or different from the length of time required for the sorting trolley center point to travel from the first target coupling position to the wrapping position of the sorter by an integer multiple of the single-pitch movement length T p of the sorter. The sorter single pitch travel time period T p represents the time required to sort the length of one pitch of trolley travel.
The conveying speed of the separated packages is adjusted according to the theoretical coupling speed v c, so that the coupling deviation value of the sorting trolley and the sorting machine is reduced. The coupling deviation value is the distance between the core point of the separated package and the conveying center line of the target trolley when the separated package is conveyed to the sorting machine at a preset package loading speed. The conveying center line of the sorting trolley is perpendicular to the running direction of the sorting trolley (namely parallel to the conveying direction of the conveying belt on the sorting trolley) and passes through the center point of the sorting trolley.
Outputting the separated package of the separation coupler, and passing through a light curtain sensor; the light curtain sensor converts the real-time position of the core point of the separated package according to the time of entering and leaving the light curtain sensor at different positions of the separated package and the real-time conveying speed of the precise coupling conveying mechanism; the precise coupling conveying mechanism adjusts the conveying speed of the separated package, and reduces the coupling deviation value of the separated package and the target trolley.
And step six, the package output by the precise coupling conveying mechanism reaches the package loading position of the sorting machine and is loaded to a sorting trolley.
Preferably, the preset packing speed is equal to the sorting trolley running speed. The travel of the sorting trolley from the first target coupling position of the sorting machine to the packing position of the sorting machine is equal to the conveying distance from the stop boundary line of the separating coupler to the packing position of the sorting machine.
Preferably, the specific process of the third step is as follows:
And 3-1, respectively judging the coordinates of the core points of each package and the occupied coupling units according to the positions and the outlines of the packages.
And 3-2, selecting the separated package.
Step 3-2-1. Dividing all packages on the split coupler into untreated packages and split packages. In the initial state, all packages on the split coupler are untreated packages.
And 3-2-2, respectively extracting the point of all the untreated packages closest to the termination boundary line of the separation coupler as the salient point of the untreated packages. All packages in the candidate set are ordered from small to large in distance from the salient point to the terminating boundary line of the separation coupler. Setting the initial value of the processing sequence number i as 1;
Step 3-2-3, judging the i-th untreated package, if the distance from the point of the i-th untreated package, which is farthest from the termination boundary line, to the termination boundary line is smaller than the distance from the protruding point of all other untreated packages to the termination boundary line, taking the i-th untreated package as a separated package, and entering the step 3-2-4; otherwise, step 3-2-5 is entered.
Step 3-2-4. Increase i by 1 and re-execute step 3-2-3.
Step 3-2-5, taking the i untreated package as a target package; judging whether a coupling unit occupied by other unprocessed packages exists right in front of any coupling unit occupied by the target package; if yes, taking the untreated package corresponding to the coupling unit occupied by the other untreated packages as a target package, and judging again. Otherwise, taking the target package as the last separated package, and entering a step four.
Preferably, the specific process of step 3-1 is as follows: respectively constructing a minimum circumscribed rectangle aiming at the outline of each package; and taking the geometric center point coordinate of the minimum circumscribed rectangle as the core point coordinate of the package. Extracting the numbers of all coupling units covered by each package; and the wrap covers the duty cycle on each coupling element. Each package covers the coupling unit with the largest coverage ratio and other coupling units with the coverage ratio of more than or equal to 40 percent as the coupling units occupied by the package.
Preferably, in the step 3-1, constructing a minimum circumscribed rectangle, and performing position correction according to the time t of image processing and the running speed v of the package; the correction process comprises the following steps: the coordinates of the four corners of the minimum circumscribed rectangle of the package are respectively shifted by v.t distances to the conveying direction of the separation coupler.
Preferably, in the fourth step, the process of selecting the target trolley for separating the package is as follows:
1) Taking any one of the separated packages as a target package; if no other separated packages exist in front of the target package; taking a sorting trolley which does not reach the first target coupling position on the sorting machine as a candidate trolley; if other separated packages exist in front of the target package; the next sorting trolley of the target trolley corresponding to the closest separated package in front of the target package is taken as the candidate trolley.
2) The theoretical coupling speed v c of the target package is calculated as follows:
vc=S/s×vr
s is the distance from the core point of the target package to the termination boundary line of the separation coupler; s is the distance from the center point of the candidate trolley to the first target coupling position of the sorting machine; v r is the running speed of the sorting trolley.
3) If the theoretical coupling speed v c≤Vmax, the candidate trolley is taken as the target trolley of the separated package.
If the theoretical coupling speed v c＞Vmax, the next sorter trolley of the candidate trolley is selected as a new candidate trolley and the theoretical speed v c is recalculated until v c≤Vmax.
Preferably, the process of adjusting the conveying speed of the separated package in the fourth step is as follows:
If v c＜vr, the coupling unit occupied by the split package conveys the split package at a speed of k 1·vc, k 1＜1;vr being the sorting trolley travel speed.
If V c＞vr, the coupling unit occupied by the separated parcel is conveying the separated parcel at the smaller of the maximum conveying speeds V max and k 2·vr; k 2 > 1.
If v c=vr, the coupling unit occupied by the split package conveys the split package at the speed of v r.
Preferably, the specific process of the fifth step is as follows:
and 5-1, calculating the distance S 0 between the core point of the separated package and the package outlet point of the precise coupling conveying mechanism.
Step 5-2. Calculate the packet time t s as follows:
s 1 is the distance from the center point of the target trolley to the second target coupling position of the sorting machine; the distance between the first target coupling position and the second target coupling position of the sorting machine is equal to the conveying distance of the precise coupling conveying mechanism.
Step 5-3, calculating a target speed v s:
step 5-4. Calculate the function of the speed transformation planning curve as follows:
Wherein t 1、t2、t3 is three times which are sequentially increased; v 0 is the initial speed of the separated package input precision coupling conveying mechanism; v 1 is the overrun speed; a is the acceleration of the precise coupling conveying mechanism along the conveying direction; v is the real-time conveying speed of the precise coupling conveying mechanism. k' taking an acceleration and deceleration coefficient; if v s≤vr, the value of k' is-1; otherwise, the value of k' is 1.
The time t 1、t2、t3 and the overrun speed v 1 are calculated by the following system of equations:
and 5-5, controlling the separated package to move along the conveying direction of the precise coupling conveying mechanism according to the speed transformation planning curve provided in the step 5-4 by the precise coupling conveying mechanism.
Preferably, the split coupler is provided with a virtual stop line. The virtual stop line is parallel to the starting boundary line of the split coupler, and the distance l=0.5 l s～0.8ls to the starting boundary line; the virtual stop line divides the split coupler into an input section and a coupling-out section. If all the unprocessed packages are in the input interval of the separation coupler and are not contacted with the virtual stop line of the separation coupler, conveying the packages occupied by all the unprocessed packages at a lower first preset speed; the value of the first preset speed is 0.1-0.5m/s; otherwise, all coupling units occupied by unprocessed packages are controlled to stop moving until all packages reaching the virtual stop line of the split coupler have been converted into split packages.
Preferably, the sorting machine is a straight-line crossed belt sorting machine; and a package feeding mechanism is arranged between the output port of the precise coupling conveying mechanism and the package feeding position of the sorting machine. The running direction of the sorting trolley of the sorting machine is consistent with the conveying direction of the package feeding conveying mechanism. The package output by the precise coupling conveying mechanism enters the package feeding conveying mechanism; the package is subjected to code scanning by a package feeding mechanism and the position of a target grid opening is determined. The conveying speed of the package conveying mechanism is equal to the running speed of the sorting trolley on the sorting machine.
Preferably, the precise coupling conveying mechanism adopts a belt conveyor; the length of the precise coupling conveying mechanism is smaller than or equal to the sorting trolley pitch of the sorting machine.
Preferably, a front-loading device is arranged in front of the separation coupler; the front-mounted bag feeding equipment adopts a belt conveyor. In step one, a pre-wrap device delivers a tiled wrap to a split coupler.
Preferably, in the second step, the camera collects video stream data of 25 frames per second; each frame of image is processed, or a key frame image is extracted every several frames for processing.
In a second aspect, the invention provides a full-automatic packing device of a straight-line crossed belt sorting machine, which is used for executing the logistic package separation coupling and full-automatic packing method; the full-automatic package loading device of the linear sorting machine comprises a separation coupler, a precise coupling conveying mechanism and a package loading conveying mechanism which are sequentially connected; the output end of the upper package conveying mechanism is in butt joint with the upper package position of the straight line cross belt sorting machine. The running direction of the sorting trolley of the straight line crossed belt sorting machine is consistent with the conveying direction of the package feeding conveying mechanism; the package output by the precise coupling conveying mechanism enters the package feeding conveying mechanism; the package is subjected to code scanning by a package feeding mechanism and the position of a target grid port is determined; the conveying speed of the package conveying mechanism is equal to the running speed of the sorting trolley on the sorting machine. The upper package conveying mechanism is provided with a code scanning device. The code scanning device is used for scanning the codes of the packages passing through the package feeding mechanism and obtaining the corresponding target grid positions of the packages.
The invention has the beneficial effects that:
1. According to the invention, the parcels which are tiled and input are output one by one through the separating coupler, and the speed of the parcels is dynamically adjusted by matching with the images acquired by the 3D camera, so that the primary coupling of the parcel core point and the target trolley center point on the sorting machine is finished on the separating coupler, and the rhythm of the parcel output by the separating coupler is matched with the operation rhythm of the sorting machine.
2. After the theoretical coupling speed v c of the separated package is obtained, the actual conveying speed is obtained by multiplying the theoretical coupling speed v c by a coefficient which is larger than 1 or smaller than 1 according to the need of the separated package to catch up with the target trolley or wait for the target trolley, so that the separated package is coupled with the target trolley in advance, and the time is reserved for dynamically correcting the coupling on the separation coupler.
3. The invention introduces a precise coupling conveying mechanism behind the separation coupler; the accurate coupling conveying mechanism can further regulate and control the time when the packages arrive at the sorting machine by controlling the conveying speed of the packages which are input one by one, so that the error of an image recognition link is reduced, and the coupling deviation between the packages and the sorting machine is reduced; meanwhile, the accurate coupling conveying mechanism introduces a speed transformation planning curve, so that the factors of acceleration time of the conveying belt and the problem of easy slippage of the package under high acceleration are considered while the theoretical package output time is not influenced, and the coupling deviation of the package and the sorting machine is further reduced.
4. The invention can fully automatically send the disordered packages to the linear sorting machine, omits the original manual ornament link and reduces the labor cost; meanwhile, the success rate and the working efficiency of sorting packages by using the separation coupler are both greatly improved.
Drawings
Fig. 1 is a schematic structural diagram of a full-automatic packing device of a straight-line cross-belt sorter provided in embodiment 1 of the present invention.
Fig. 2 is a flowchart of embodiment 2 of the present invention.
FIG. 3 is a schematic diagram of the construction of the minimum bounding rectangle in step 3-1 of example 2 of the present invention.
FIG. 4 is a schematic diagram of the replacement of the target package in step 3-2-5 of example 2 of the present invention.
Fig. 5 is a graph showing the speed change plan in the case where the acceleration/deceleration coefficient k' is 1 in step 5-4 of embodiment 2 of the present invention.
Fig. 6 is a graph showing the speed change plan in the case where the value of the acceleration/deceleration coefficient k' is-1 in step 5-4 of embodiment 2 of the present invention.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
Example 1
As shown in fig. 1, the full-automatic packing device of the straight-line crossed belt sorting machine comprises a front-mounted packing feeding device 1, a separation coupler 2, a precise coupling conveying mechanism 3 and a packing conveying mechanism 4 which are sequentially connected. The output port of the upper package conveying mechanism 4 is connected with the upper package position of the sorting machine 5. In this embodiment, the sorter 5 is a straight-line cross-belt sorter 5, the conveying direction of which is identical to that of the upper-packet conveying mechanism 4, and the upper-packet position is an input end, and is directly abutted with the output port of the upper-packet conveying mechanism 4.
The front-mounted bag feeding equipment 1 and the precise coupling conveying mechanism 3 adopt belt conveyors; the widths of the front-mounted package feeding equipment 1, the separation coupler 2, the precise coupling conveying mechanism 3, the package feeding conveying mechanism 4 and the sorting machine 5 are equal; the packages can be ensured to enter the sorter 5 smoothly without blocking without laterally adjusting the package position.
The separation coupler 2 includes a 3D vision camera, a coupling unit 2-1, a driving motor, and a controller. A separation area is arranged in the separation coupler 2, and the separation area is wrapped for separation; the separation zone comprises 6 rows and 5 columns of coupling units 2-1, each coupling unit 2-1 being provided with a drive motor for individually controlling the speed of the packages on the coupling unit 2-1. The arrangement direction of the coupling units 2-1 in each row of the coupling units 2-1 is identical to the conveying direction of the coupling units 2-1.
The decoupling coupler 2 is provided with a virtual stop line 2-2. The virtual stop line 2-2 is parallel to the starting boundary line of the split coupler 2, and the distance l=l s·2/3;ls to the starting boundary line is the length of the split coupler 2. The virtual stop line 2-2 divides the split coupler 2 into an input section and an output section. The input section is a region between the virtual stop line 2-2 and the start boundary line. The coupling-out section is the area between the virtual stop line 2-2 and the termination boundary line. The virtual stop line 2-2 is not a real physical structure, but an algorithmically set boundary.
The 3D vision camera can shoot all packages on the separation coupler 2, obtain the position data of the packages, and transmit the position data to the controller; the controller is capable of processing the received location data to obtain the center point coordinates of each package.
The separating coupler 2 is used for completing preliminary matching of packages and sorting carts.
The accurate coupling conveying mechanism 3 is used for accurately controlling the conveying speed of the packages according to the position of the sorting trolley on the sorting machine 5 and entering the time point of the package conveying mechanism, so that the packages can stably enter one sorting trolley after being scanned by the package conveying mechanism, and cannot enter between the two sorting trolleys.
The junction of the separation coupler 2 and the accurate coupling conveying mechanism 3 is provided with a light curtain sensor. The light curtain sensor is used for collecting the position information of the package entering the precise coupling and conveying mechanism 3 so that the precise coupling and conveying mechanism 3 can adjust the center of the package to a position aligned with the center line of the sorting machine 5; and further position matching the packages with the sorting carts on the sorting machine 5.
The conveying speed of the upper package conveying mechanism 4 is equal to the running speed of the sorting trolley on the sorting machine 5. The conveying distance of the precise coupling conveying mechanism 3 is equal to the sorting trolley pitch on the sorting machine 5, so that the fact that the front package and the rear package are simultaneously positioned in the precise coupling conveying mechanism 3 can be avoided; the conveying distance of the package conveying mechanism 4 is an integral multiple of the pitch of the sorting trolley on the sorting machine 5 so as to simplify the control of the separation coupler 2; that is, only when the center point of the parcel reaches the termination boundary line of the separation coupler 2, the center point of one sorting trolley reaches the parcel loading position of the sorting machine 5, and the parcel sorting trolley can be considered to complete preliminary matching. Only when the center point of the parcel is controlled to reach the end part of the output end of the precise coupling conveying mechanism 3, the center point of one sorting trolley reaches the parcel loading position of the sorting machine 5, and the precise matching of the parcel sorting trolley can be considered.
In this embodiment, the 3D vision camera 1s outputs 30 frames of data; the sorting trolley pitch of the sorting machine 5 is 500mm; the deviation of the adjacent package spacing after coupling relative to the sorting trolley pitch is within the range of 5 mm; etherCAT communication is adopted between the coupling unit 2-1 and the controller, and the communication period is 4ms.
Example 2
As shown in fig. 2, a method for separating, coupling and fully automatically packing logistic packages is applied to the fully automatic packing device of the straight-line cross-belt sorter described in embodiment 1. The method comprises the following steps:
Step one, a package entering process.
The front package feeding equipment 1 conveys tiled packages to the separation coupler 2 through a conveying belt, and the packages move on the separation coupler 2 at a low speed and wait for separation;
Step two, package data acquisition
The 3D depth camera performs image acquisition on a separation area of the separation coupler 2 according to a preset shooting frequency in a period T to acquire a package image, so as to acquire package position data, and the package position data is transmitted to the controller after package sticking processing; the controller analyzes the profile and the position coordinates of the package according to the received position data. In this embodiment, the camera collects 25 frames per second of video stream data; processing each frame of image; therefore, the period T takes a value of 0.04s. And (3) re-executing the third to fourth steps every time a new image is acquired.
Step three, identifying and classifying the packages
3-1. Package occupancy analysis of coupling unit 2-1.
As shown in fig. 3, the minimum bounding rectangle (normalized by area minimization) is constructed separately for the outline of each parcel. Then, correcting the coordinates of the four corners of the minimum circumscribed rectangle according to the time t of image processing and the running speed v of the package; the correction method is that the coordinates of the four corners of the minimum circumscribed rectangle of the package are respectively shifted forward (package conveying direction) by v.t distance. Recording the coordinates of four corners of the minimum circumscribed rectangle after correction and the coordinates of the geometric center point; and taking the geometric center point coordinate of the minimum circumscribed rectangle as the core point coordinate of the package.
Extracting the numbers of all the coupling units 2-1 covered by each package; and the coverage duty cycle of the wrap on each coupling element 2-1 (i.e., the ratio between the area covered by the corresponding wrap on coupling element 2-1 and the total area).
Each package covers the coupling unit 2-1 with the largest proportion and other coupling units 2-1 with the proportion of more than or equal to 40 percent as the coupling units 2-1 occupied by the package; each package establishes a corresponding occupation set; the occupancy sets include the numbers of the corresponding coupling units 2-1 wrapping all occupancy.
In this embodiment, the data transmission between the controller and the 3D vision camera adopts TCP/IP protocol.
3-2 Dividing parcel types
3-2-1. All packages on the split coupler 2 are divided into untreated packages and split packages. In the initial state, all packages on the split coupler 2 are untreated packages.
3-2-2. The points of all the untreated packages closest to the terminating boundary line of the split coupler 2 are extracted as the salient points of the untreated packages, respectively. All packages in the candidate set are ordered from small to large in distance from the salient point to the terminating boundary line of the split coupler 2. Setting the initial value of the processing sequence number i as 1;
3-2-3, judging the i-th untreated package, if the distance from the point of the i-th untreated package, which is farthest from the termination boundary line, to the termination boundary line is smaller than the distance from the protruding point of all other untreated packages to the termination boundary line, taking the i-th untreated package as a separated package, and entering the step 3-2-4; otherwise, step 3-2-5 is entered.
3-2-4. Increase i by 1 and re-execute step 3-2-3.
3-2-5. Taking the i untreated package as a target package; as shown in fig. 4, if any coupling unit 2-1 occupied by the target package exists in front of the coupling unit 2-1 occupied by another unprocessed package, the unprocessed package corresponding to the coupling unit 2-1 occupied by another unprocessed package is re-determined as the target package. Otherwise, taking the target package as the last separated package, and entering a step four.
And step four, conveying and controlling the untreated packages and the separated packages.
4-1, If all the unprocessed packages are in the input interval of the separation coupler 2 and are not contacted with the virtual stop line 2-2 of the separation coupler 2, conveying the packages occupied by all the unprocessed packages at a lower first preset speed; the value of the first preset speed is 0.1-0.5m/s; otherwise, all packages that have reached the virtual stop line 2-2 of the split coupler 2 are controlled to stop moving, all coupling units 2-1 occupied by the unprocessed packages, until all packages have been converted into split packages.
And 4-2, respectively initially selecting a target trolley for each separated package.
Taking any one of the separated packages as a target package; if no other separated packages exist in front of the target package; taking a sorting trolley on the sorting machine 5 which does not reach a first target coupling position preset on the sorting machine as a candidate trolley; if other separated packages exist in front of the target package; the next sorting trolley of the target trolley corresponding to the closest separated package in front of the target package is taken as the candidate trolley.
4-3, Calculating the theoretical coupling speed v c of the target package as follows:
vc=S/s×vr
S is the distance from the core point of the target package to the termination boundary line of the separation coupler 2; s is the distance from the center point of the candidate trolley to the first target coupling position of the sorter 5; v r is the running speed of the sorting trolley.
The theoretical coupling speed v c is a theoretical speed at which the target package completes coupling with the target cart when reaching the terminating boundary line of the decoupler 2. The specific meanings of the target package and the target trolley are as follows: the moment at which the core point of the separated parcel is conveyed to the stop boundary line of the separation coupler 2 is the same as the moment at which the centre point of the corresponding target trolley reaches the first target coupling position of the sorting machine.
4-4. If the theoretical coupling speed v c≤Vmax, the candidate trolley is taken as the target trolley of the separated package.
If the theoretical coupling speed v c＞Vmax, the next sorter 5 trolley of the candidate trolley is selected as a new candidate trolley and the theoretical speed v c is recalculated until v c≤Vmax.
4-4. If V c＜vr, the coupling element 2-1 occupied by the split package is conveying the split package at the smaller of the maximum conveying speeds V max and k 1·vc, k 1＜1;k1 may take a fixed value (e.g., 0.8); and dynamic value can be adopted, and the smaller the ratio of v c to v r is, the smaller the value of k 1 is.
If v c＞vr, then the coupling unit 2-1 occupied by the split package delivers the split package at the speed of k 2·vr; k 2>1.K2 may take either a fixed value (e.g., 1.2); and dynamic value can be adopted, and the larger the ratio of v c to v r is, the larger the value of k 2 is.
If v c=vr, the coupling unit 2-1 occupied by the split package conveys the split package at the speed of v r.
The third step and the fourth step are re-executed every time the image is shot, and the running speed of each package can be dynamically updated once in each period T; so that the packages output by each separating coupler 2 can be correspondingly coupled to the sorting trolley.
In the adjusting process, the coupling deviation value of the sorting trolley and the sorting machine is gradually reduced; the coupling deviation value is the distance between the core point of the separated package and the conveying center line of the trolley at which the separated package is separated when the separated package is conveyed to the sorting machine. The conveying center line of the sorting trolley is perpendicular to the running direction of the sorting trolley (namely parallel to the conveying direction of the conveying belt on the sorting trolley) and passes through the center point of the sorting trolley. The introduction of coefficients k 1 and k 2 helps to increase the speed at which the coupling offset value decreases.
And fifthly, carrying out accurate coupling of the package and the target trolley by the accurate coupling conveying mechanism 3.
5-1, When a separated package outputs the separated coupler 2, using the time of entering and leaving the light curtain sensor at different positions of the separated package and the conveying speed of the precise coupling conveying mechanism 3, converting the real-time position of the core point of the separated package; and calculating the distance S 0 between the core point of the separated package and the package outlet point of the precise coupling conveying mechanism 3.
5-2. Calculate the packet time t s as follows:
Wherein S 1 is the distance from the center point of the target cart to the second target coupling position of the sorter 5; the distance between the first target coupling position and the second target coupling position of the sorting machine 5 is equal to the conveying distance of the precise coupling conveying mechanism 3.
5-3, Calculating a target speed v s:
5-4. Calculating a function of the speed transformation planning curve as follows:
Wherein t 1、t2、t3 is three times which are sequentially increased; v 0 is the initial speed of the separated package input precise coupling conveying mechanism 3; v 1 is the overrun speed; a is the acceleration of the precise coupling conveying mechanism 3 along the conveying direction, and the value of the acceleration is preset, so that the requirement that relative sliding does not occur when the package is accelerated or decelerated by the acceleration is met; v is the real-time conveying speed of the precise coupling conveying mechanism 3. k' taking an acceleration and deceleration coefficient; if v s≤vr, the value of k' is-1; otherwise, the value of k' is 1. The speed change schedule is shown in fig. 5 and 6.
The time t 1、t2、t3 and the overrun speed v 1 are calculated by the following system of equations:
5-5, controlling the separated packages by the precise coupling conveying mechanism 3 to move along the conveying direction of the precise coupling conveying mechanism 3 according to the speed transformation planning curve provided by the step 5-4; the speed of the separated package when leaving the precise coupling conveying mechanism 3 can be guaranteed to be consistent with the running speed of the sorting trolley while the separated package is precisely coupled with the sorting machine 5, so that the problem of package position deviation caused by abrupt speed change is avoided.
Step six, the package output by the precise coupling conveying mechanism 3 enters the package feeding conveying mechanism 4; the upper package conveying mechanism is provided with a code scanning device. After the package is scanned by the code scanning device and the target grid is determined by the package conveying mechanism 4, the package is conveyed to the target trolley. And the target trolley conveys the packages to the corresponding grid openings and outputs the packages, so that full-automatic sorting of the packages is realized. In the embodiment, the code scanning device adopts six-sided scanning equipment, can identify the bar code which is oriented randomly on the package, and solves the problem that the code cannot be scanned normally when the bar code on the package faces downwards.
In some embodiments, the target cart selected in step four is not the sorting cart to which the package ultimately arrives; instead, the target trolley is only used as a scaled intermediate variable, i.e., the time when the core point of the package reaches the wrapping position of the sorter and the time when the center point of the target trolley reaches the wrapping position of the sorter may differ by an integer multiple of the sorter single-pitch movement time period T p, where the sorter single-pitch movement time period T p represents the time required for the sorter trolley to travel one pitch.

Claims (9)

1. A logistics package separation coupling and full-automatic packing method; the method is characterized in that: the automatic packaging device comprises a separation coupler (2) and a precise coupling conveying mechanism (3) which are connected in sequence; the split coupler (2) comprises a plurality of coupling units (2-1) arranged in a matrix shape and a camera capable of shooting each coupling unit (2-1); each coupling unit (2-1) adopts an independently controlled conveyer belt structure; a light curtain sensor is arranged at the joint of the separation coupler (2) and the precise coupling conveying mechanism (3);
the logistics package separation coupling and full-automatic packing method comprises the following steps:
Step one, conveying the package to a separation coupler (2);
Step two, collecting package data; the camera performs periodic image acquisition on the separation coupler (2); after each image acquisition, extracting the outline and the core point position of each package in the obtained image, and re-executing the third and fourth steps;
Dividing all packages on the separation coupler (2) into unprocessed packages and separated packages; according to the positions and the outlines of the packages, the unprocessed packages are converted into separated packages one by one, so that the conveying control of each separated package can not influence the conveying speed of all the unprocessed packages;
Step four, sorting trolleys serving as target trolleys are respectively selected for the separated packages, and theoretical coupling speeds v c of the separated packages are respectively calculated; the theoretical coupling speed v c satisfies the following condition: the length of time that the core point of the separated package is conveyed to the stop boundary line of the separation coupler (2) at the theoretical coupling speed v c is equal to the length of time that the center point of the corresponding target trolley runs to the first target coupling position of the preset sorting machine;
Adjusting the conveying speed of the separated packages according to the theoretical coupling speed v c so that the coupling deviation value of the sorting trolley and the sorting machine is reduced; the coupling deviation value is the distance between the core point of the separated package and the conveying center line of the target trolley when the separated package is conveyed to the sorting machine at a preset package loading speed;
Step five, outputting the separated package of the separation coupler (2) to pass through a light curtain sensor; the light curtain sensor converts the real-time position of the core point of the separated package according to the time of entering and leaving the light curtain sensor at different positions of the separated package and the real-time conveying speed of the precise coupling conveying mechanism (3); the precise coupling conveying mechanism (3) adjusts the conveying speed of the separated package, and reduces the coupling deviation value of the separated package and the target trolley;
The specific process of the fifth step is as follows:
step 5-1, calculating the distance S 0 between the core point of the separated package and the package outlet point of the accurate coupling conveying mechanism (3);
step 5-2. Calculate the packet time t s as follows:
；
S 1 is the distance from the center point of the target trolley to the second target coupling position of the sorting machine (5); the distance between the first target coupling position and the second target coupling position of the sorting machine (5) is equal to the conveying distance of the precise coupling conveying mechanism (3); v r is the sorting trolley running speed;
Step 5-3, calculating a target speed v s;
；
step 5-4. Calculate the function of the speed transformation planning curve as follows:
；
Wherein t 1、t2、t3 is three times which are sequentially increased; t is the time for which the separated package is input into the precise coupling conveying mechanism (3); v 0 is the initial speed of the separated package input precise coupling conveying mechanism (3); v 1 is the overrun speed; a is the acceleration of the precise coupling conveying mechanism (3) along the conveying direction; v is the real-time conveying speed of the precise coupling conveying mechanism (3); k' taking an acceleration and deceleration coefficient; if v s≤vr, the value of k' is-1; otherwise, the value of k' is 1;
The time t 1、t2、t3 and the overrun speed v 1 are calculated by the following system of equations:
；
Step 5-5, the precise coupling conveying mechanism (3) controls the separated packages to move along the conveying direction of the precise coupling conveying mechanism (3) according to the speed transformation planning curve provided by the step 5-4;
And step six, the package output by the precise coupling conveying mechanism (3) reaches the package loading position of the sorting machine and is loaded to a sorting trolley.
2. The method for separating and coupling logistics packages and fully automatic packaging according to claim 1, wherein the method comprises the following steps: the preset packing speed is equal to the running speed of the sorting trolley; the travel of the sorting trolley from the first target coupling position of the sorting machine to the packing position of the sorting machine is equal to the conveying distance from the termination boundary line of the separating coupler (2) to the packing position of the sorting machine.
3. The method for separating and coupling logistics packages and fully automatic packaging according to claim 1, wherein the method comprises the following steps: the specific process of the third step is as follows:
Step 3-1, according to the position and the outline of each package, respectively judging the coordinates of the core point of each package and the occupied coupling unit (2-1);
Step 3-2, selecting separated packages;
Step 3-2-1, dividing all packages on the separation coupler (2) into unprocessed packages and separated packages; in the initial state, all packages on the separation coupler (2) are unprocessed packages;
step 3-2-2, respectively extracting points of all untreated packages closest to the termination boundary line of the separation coupler (2) as protruding points of the untreated packages; sorting all packages in the candidate set according to the distances from the salient points to the termination boundary line of the separation coupler (2) from small to large; setting the initial value of the processing sequence number i as 1;
Step 3-2-3, judging the i-th untreated package, if the distance from the point of the i-th untreated package, which is farthest from the termination boundary line, to the termination boundary line is smaller than the distance from the protruding point of all other untreated packages to the termination boundary line, taking the i-th untreated package as a separated package, and entering the step 3-2-4; otherwise, enter step 3-2-5;
step 3-2-4. Increasing i by 1 and re-executing step 3-2-3;
Step 3-2-5, taking the i untreated package as a target package; judging whether a coupling unit (2-1) occupied by other unprocessed packages exists right in front of any coupling unit (2-1) occupied by the target package; if yes, taking the untreated package corresponding to the coupling unit (2-1) occupied by other untreated packages as a target package, and judging again; otherwise, taking the target package as the last separated package, and entering a step four.
4. The method for separating and coupling logistics packages and fully automatic packaging according to claim 3, wherein the method comprises the following steps: the specific process of the step 3-1 is as follows: respectively constructing a minimum circumscribed rectangle aiming at the outline of each package; taking the geometric center point coordinate of the minimum circumscribed rectangle as the core point coordinate of the package; extracting the numbers of all the coupling units (2-1) covered by each package; and the wrap covers the duty cycle on each coupling unit (2-1); each package covers the coupling unit (2-1) with the largest ratio by itself, and other coupling units (2-1) with a ratio greater than or equal to 40% as the coupling units (2-1) occupied by the package.
5. The method for separating and coupling logistics packages and fully automatic packaging according to claim 4, wherein the method comprises the following steps: constructing a minimum external rectangle in the step 3-1, and carrying out position correction according to the time t of image processing and the running speed v of the package; the correction process comprises the following steps: the coordinates of the four corners of the minimum circumscribed rectangle of the package are respectively shifted by v.t distances to the conveying direction of the separation coupler (2).
6. The method for separating and coupling logistics packages and fully automatic packaging according to claim 1, wherein the method comprises the following steps: in the fourth step, the process of selecting the target trolley for separating the package is as follows:
1) Taking any one of the separated packages as a target package; if no other separated packages exist in front of the target package; taking a sorting trolley which does not reach the first target coupling position on the sorting machine (5) as a candidate trolley; if other separated packages exist in front of the target package; the next sorting trolley of the target trolley corresponding to the closest separated package in front of the target package is taken as a candidate trolley;
2) The theoretical coupling speed v c of the target package is calculated as follows:
vc=S/s×vr
S is the distance from the core point of the target package to the termination boundary line of the separation coupler (2); s is the distance from the center point of the candidate trolley to the first target coupling position of the sorting machine (5); v r is the running speed of the sorting trolley;
3) If the theoretical coupling speed V c≤Vmax is the theoretical coupling speed V c≤Vmax, the candidate trolley is taken as a target trolley of the separated package, and V max is the maximum conveying speed of the coupling unit (2-1) occupied by the separated package;
If the theoretical coupling speed v c＞Vmax, the next sorter (5) car of the candidate car is selected as a new candidate car and the theoretical speed v c is recalculated until v c≤Vmax.
7. The method for separating and coupling logistics packages and fully automatic packaging according to claim 1, wherein the method comprises the following steps: the process of adjusting the conveying speed of the separated packages in the fourth step is as follows:
if V c＜vr, the coupling unit (2-1) occupied by the separated parcel conveys the separated parcel at the smaller of the maximum conveying speeds V max and k 1·vc, k 1＜1;vr being the sorting trolley running speed;
If v c＞vr, then the coupling unit (2-1) occupied by the split package conveys the split package at a speed of k 2·vr; k 2 > 1;
If v c=vr, the coupling unit (2-1) occupied by the split package conveys the split package at the speed of v r.
8. The method for separating and coupling logistics packages and fully automatic packaging according to claim 1, wherein the method comprises the following steps: a virtual stop line (2-2) is arranged on the separation coupler (2); the virtual stop line (2-2) is parallel to the start boundary line of the split coupler (2), and the distance l=0.5 l s～0.8ls to the start boundary line; the virtual stop line (2-2) divides the split coupler (2) into an input section and a coupling output section; if all the unprocessed packages are in the input interval of the separation coupler (2) and are not contacted with the virtual stop line (2-2) of the separation coupler (2), conveying the packages occupied by all the unprocessed packages at a lower first preset speed; otherwise, all packages that have reached the virtual stop line (2-2) of the split coupler (2) are converted into split packages by controlling all coupling units (2-1) occupied by the unprocessed packages to stop moving.
9. Full-automatic packing device of straight line intersection area sorting machine, its characterized in that: for performing the logistic wrap separation coupling and full automatic packing method of any one of claims 1-8; the full-automatic packing device of the straight-line crossed belt sorting machine comprises a separation coupler (2), an accurate coupling conveying mechanism (3) and a packing conveying mechanism (4) which are connected in sequence; the output end of the upper package conveying mechanism (4) is in butt joint with the upper package position of the straight line crossed belt sorting machine; the running direction of the sorting trolley of the straight line crossed belt sorting machine is consistent with the conveying direction of the upper package conveying mechanism (4); the package output by the precise coupling conveying mechanism (3) enters the package feeding conveying mechanism (4); the package is subjected to code scanning by a package feeding mechanism (4) and the position of a target grid port is determined; the conveying speed of the upper package conveying mechanism (4) is equal to the running speed of a sorting trolley on the sorting machine (5); the upper package conveying mechanism is provided with a code scanning device; the code scanning device is used for scanning the codes of the packages passing through the package feeding mechanism (4) and obtaining the corresponding target grid positions of the packages.
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