EP1213057A2 - Method for automated sorting of objects and composing assortments - Google Patents

Abstract

The invention relates to a method for the automated sorting of objects and the compilation of assortments with objects (3), the objects (3) being moved from a belt conveyor (2) into the work area of controllable ones as inlays (E ₁ , E ₂ , E ₃ , E ₄ ) used handling devices are promoted. The inserts (E ₁ , E ₂ , E ₃ , E ₄ ) grip the objects (3) and bring them into a sorting position provided according to a sorting instruction.

In the case of a variable specification of different sorting regulations, it is provided according to the invention that each object (3) is positioned in a position close to the assortment position by a handling device which is arranged in front of the insert (E ₁ , E ₂ , E ₃ , E ₄ ) and is used as a deposit (A ₁ A ₂ ) is placed on the belt conveyor (2).

Description

The invention relates to a method for automated Sort objects and assemble assortments of objects.

In known sorting methods, objects become controllable Handling devices gripped and in trays (Trays), which pass through on a belt conveyor. Every gripped object is handled by the handling device assigned to an assortment, the position of which Assortment of the control of the handling device is determined. Quantity are often used as sorting criteria the types of objects to be merged into the assortment specified or their individual weight or approximately the total weight of an assortment.

WO 99/28057 describes a method for automated Group known in which the objects are in random order abandoned to the belt conveyor in a constant flow and then by handling devices be brought into the intended assortment position. The Assortment items are in this known method provided on the belt surface of the feeding belt conveyor, with an upstream detection device random position and orientation of the objects and one Control unit displays. Depending on the state of order found the control unit determines such sorting positions and controls the handling robots accordingly assumes that the robots have the greatest possible sorting performance work.

In a well-known sorting plant there is for every object type an associated handling device is provided as an insert, which of the objects assigned to it grabs and stores in the appropriate sorting position. When sorting multiple object types into assortments therefore several processing stations required, which with known methods mostly in a production line interact. The handling devices work due to the required sorting performance is closely linked. The known sorting systems are therefore with the automated handling devices for certain Sorting tasks designed, with a variation of the Sorting tasks is difficult to implement. An upgrade when changing the sorting task often requires another Handling device, which is associated with high costs. In addition, the known methods for automated Sorting objects in sorting systems that have several interacting handling devices, not always maximized due to conditional chaining Overall efficiency can be achieved because of the sorting speed with all handling devices must be synchronized. Such handling devices must therefore be used work at low speed, which is basically the one intended for this robot Sort task could perform faster and for reasons the synchronism of the entire system on slower working Robots have to wait.

The present invention is based on the object Process for automated sorting of objects create which with variable specification different Sorting rules enables faster sorting.

This object is achieved with the features of Claim 1 solved.

Each trailer puts the objects taken from the supply in a position first on the belt conveyor z. B. near the insert tray. The position is after the transport the objects in the work area of the inserts near the desired ones Sorting positions, which means the commute to work Depositors are short. This allows the inlay at high Driving speed additional work steps. The Performance of the trailer is optimized when the objects are in an arrangement similar to the group status in the stock the belt conveyor are put on. Remove the trailer the objects in groups in the supply; for example with an order of the objects in the store in shifts with each matrix arrangement can be arranged by rows of objects taken from the matrix or parts of the rows in the stock and placed on the belt conveyor. The objects from the In this way, stocks are separated when hanging up and can be stored in easily accessible position on the belt conveyor by the inlayers are quickly brought into the sorting positions.

When sorting and compiling several object types of assortments with specified quantities of different objects are expediently those objects an object type with the higher one after the Sorting rules per number of items provided placed closer to the sorting position on the belt conveyor than the objects of the other object types. This creates shorter for the types of objects that are frequently to be handled Work paths for the robots and a correspondingly high one Overall speed.

The objects in tracks are advantageously the same Object types placed in the conveying direction of the belt conveyor. The assortment items can be roughly parallel to the Objects can be provided on the belt conveyor. At a Sorting the objects in containers will be sorted into any Positions continuously placed on the belt, whereby the objects of the sort with the largest to be sorted Number of pieces per container immediately adjacent to the container is launched. The distances between the groups at the same time objects that have been removed and placed on stock advantageously evenly, according to the intended Quantity per assortment and the number at the same time placed objects a periodically recurring Lay-on pattern results. The distances are determined by the control unit taking into account the number of simultaneously placed Objects, i.e. the original order the objects in the stock selected so that the depositors with maximum possible movement speed can work. The control unit tunes all the trailers and the subordinate ones Depositors taking into account their respective Handling services depend on each other.

The method according to the invention enables the rigid chaining of several sorting robots in one production line and linking the depositor to a specific one Object type, which makes the overall efficiency of the Sorting process is increased and not by the individual Performance of the slowest working Handling device is limited. The objects can be in a quick lay-on operation simply in the stock similar formation are placed on the belt conveyor, where the hanging up is determined by the group spacing Pattern a light coordination of work cycles the insert enables. The overlay pattern is from the control unit of the sorting system depending on the given sorting rules taking into account the respective performance of the applicable handling devices determined and accordingly the optimal transport speed of the belt conveyor.

With the two-stage sorting process, the depositors can and the hangers that are connected by the belt conveyor are connected, spatially separated. On this way a powerful sorting system can be found in every available space is modular become.

With the two-stage sorting system with overlays and inlays the overlay pattern is dependent on the given Sorting rules determined so that the movements of the insert can be optimized. It is found that the capacity of a depositor is not sufficient in order to cover all relevant items in high quantities per assortment Sorting objects of that sort becomes less busy Inserted to fill the gap. Everyone Depositor can handle any of the objects to be sorted. The pattern and control of the Handling devices matched so that the insert as evenly as possible for sorting processes that are higher Sorting performance and those that require less sorting performance need to be used.

In a preferred embodiment of the invention, a Recognition device between the feeder and the feeder, for example a camera arrangement, the actual one Location of the objects on the belt conveyor detected and the Gripping movements of the inserts for the individual objects corrected. In this way, individual slipping Objects are considered when hanging up, and these objects can be sorted into the provided assortments are brought. You can also defective products recognized and from sorting be excluded, for example in the case of Sorting broken pastry baked goods.

High overall arrangement efficiencies are achieved if the smallest common one when determining the overlay pattern Multiples of the intended number of pieces Object types per assortment and the number of these objects per placed group is calculated. From these values, the are then related to the respective object types the control unit the smallest common multiple as the number of ranges of the overlay pattern, whereby the entire range from this range, in each period number of the respective pattern Object type results. This is useful for this pattern intended belt section with the available work area the depositor compared. Provides the control unit determined that the required belt length over the available working area of the depositor, for example for large quantities one of the object types in Comparison to the other object types to be sorted, see above is achieved by placing these objects in multiple rows in the long determined object track the intended belt route shortened adapted.

A further optimization of the sorting performance is achieved if the group distances of the object groups are one for the Operation of the insert pattern determined on the closest, achievable with the performance of the trailer Value can be set and based on the corrected Group spacing an adapted layout pattern is determined. This adjustment of the overlay pattern can be based on the above calculation based on the common Multiples of the factors involved take place. Are several Lay-on patterns with different distances possible, see above sets the control unit by varying the possible support patterns, the belt speed of the belt conveyor, the Varying the distance between the shells and the number of used handling devices the maximum achievable Sorting performance. The inserts can be placed in groups be summarized, the feeder station a corresponding overlay pattern of the ones to be sorted Objects on the belt conveyor, which all groups of inserts justice. Depending on the required Sorting performance in coordination with the determined as optimal Lay-on samples can be made using a sorting system has several inserts and several inserts which each specified sorting rule, if necessary just a few of the handling devices available be carried out, each for themselves by operation with the inventive method optimal are busy. The sorting system is the inventive Process for a wide variety of sorting tasks can be used variably, only the robots accordingly are to be programmed by the control unit and complex structural changes are not required.

An embodiment of the invention is shown below the drawing explained in more detail.

Show it:

Fig. 1

a schematic view of a sorting plant,

Fig. 2

a flow chart of a sorting process,

Fig. 3

1 shows a schematic representation of an overlay pattern,

Fig. 4

another representation of a lay-on pattern.

The sorting system 1 shown in FIG. 1 comprises a plurality of handling devices A ₁ , A ₂ , E ₁ , E ₂ , E ₃ , E ₄ for the automated assembly of objects of different types into individual, predefinable ranges. The sorting system 1 further comprises a belt conveyor 2, the objects 3 to be sorted being placed on the belt by supports A ₁ , A ₂ and conveyed in the direction of movement 5 by the belt conveyor 2 to second handling devices E ₁ , E ₂ , E ₃ , E ₄ become. The second handling devices are used as inlays E ₁ , E ₂ , E ₃ , E ₄ , which grip the objects 3 on the belt conveyor 2 and sort them into trays or containers 4 according to the specified sorting instructions. The inserts E ₁ , E ₂ , E ₃ , E ₄ essentially consist of a gripping robot 6, which is held in a support frame 7 and can move to any position in the width of the belt conveyor 2 in its working area. The sorting system 1 can also have further handling devices, as is indicated by the additional layer shown in dashed lines. The objects are removed from the supplies 12 by the supports A ₁ , A ₂ by means of gripping arms 9 and placed on the belt conveyor 2. The feeder A ₁ , A ₂ and the feeder E ₁ , E ₂ , E ₃ , E ₄ are controlled by a control unit 10 and coordinated according to the specified sorting instructions. The control unit 10 puts the appropriate number of handling devices into operation in accordance with the required sorting performance and the sorting task and taking into account the sorting method according to the invention.

The objects 3 are sorted into trays 4 by the inlays E ₁ , E ₂ , E ₃ , E ₄ , which are placed on the belt conveyor 2 at the predetermined sorting positions and at preselected intervals and are fed to the inserts with the objects 3. The objects 3 are placed on the belt in the vicinity of the sorting positions, that is to say adjacent to the trays 4, which results in short work paths for the inlays E ₁ , E ₂ , E ₃ , E ₄ and rapid sorting is possible. The position and the orientation of the objects on the belt conveyor 2 is detected by an optical detection device 11. On the basis of the signal 13 from the detection device 11, the control unit corrects the activation of the inserts E ₁ , E ₂ , E ₃ , E ₄ , defects of individual objects also being detected. These defective goods are not gripped by the inserts and, after passing through the inserts, fall into a reject basket, for example at the end of the belt conveyor 2.

In the supply 12, the objects 3 of the respective type are in large numbers in an orderly state, which, for. B. is convenient for storage or shipping. Thus, the objects 3 can be provided in several layers in rows lying side by side in a matrix. The objects 3 are placed on the belt by the layers A ₁ , A ₂ in a formation similar to the order state in the supply 12, several objects 3 being removed in each case and simultaneously being placed on the belt conveyor 2. The associated handling process is quick and easy. The sorting method according to the invention is explained in more detail below with reference to FIGS. 2 to 4.

The objects to be sorted, baked goods of different types in the present exemplary embodiment, are placed on the belt in the conveying direction in tracks Sp by the same types of baked goods I, II, III, parallel to the trays S. This results in a lay-up pattern M corresponding to the number of biscuits placed at the same time and the intended number of pieces per bowl S, which is characterized by the uniform spacing between the biscuit groups placed at the same time. The lay-up pattern shown in FIG. 3 is an example of a sorting of three types of pastry into assortments, seven types of pastry type I, five types of pastry type II and three types of pastry type III each having to be sorted into the trays S. A complete lay-up pattern is shown, which is repeated periodically by joining the respective strip sections X _W for the lay-up pattern. Four trays S with pastries are to be sorted per period of the pattern; the shells are provided with the reference numerals 1 to 4. The trays S are set up by the overlayers at the assortment positions that are specified for the inlays for storing the gripped objects O for the respective assortments.

The control unit determines such a hanging pattern, which, depending on the specified sorting rule Efficiency of the insert and insert that can be used optimally exhausted and the usable handling devices coordinates and coordinates their movements. The handling devices used, especially the inserts, as evenly as possible for sorting processes that require high sorting performance and those that require less sorting performance become.

The products, e.g. B. Pastries of the same type are advantageous at the same time on the intended track Belt conveyor stored, the distances X [1], X [2] and X [3] of the applied groups are even. In the present Four biscuits are exemplary embodiment placed on the belt conveyor; this size will according to the invention taking into account the state of order of the objects made available in the stock.

When determining a suitable lay-up pattern, the entire sorting task is first distributed to the robots in individual handling steps in step R according to the flow chart in FIG. 2. A required belt section X _{W is} determined in accordance with the sorting specification, on which a period of the lay-on pattern can be arranged. On this belt section, in the individual tracks Sp of the pastry types I, II, III, pastry pieces of the respective types are placed in the intended ratio, as is later to be sorted into the trays. The lowest common multiple is formed from the intended number of pieces of a pastry type per assortment and the number of these types of pastries per placed group G. Since each type of biscuit group G with four pieces is placed on the belt conveyor, the sorting instructions result in seven pieces, five pieces, three pieces, the smallest common multiples 28, 20 and 12.These values referring to the types of biscuits become again The smallest common multiple is calculated as the number of assortments that corresponds to the number of containers that have to be placed on the belt conveyor for each lay-up pattern. In the present exemplary embodiment, this results in a number of four shells S per lay-on pattern.

From the distance X _{RL of} a group G, with a single row of pastries, the band length X _W results from the condition that seven groups, i.e. 28 pieces of pastries I are to be placed in a sample period, as an approximate value when determining the lay-up pattern. The biscuits of the biscuit types II, III to be sorted in a smaller number are placed evenly spaced apart from one another on the intended belt length X _W. With the distances X [i] determined in this way between the groups of the individual types of pastries and the distances X _{S of} the trays S, the control unit determines the available work area of the inserts and, taking into account the possible sorting speed and sorting performance, determines whether the inserts with the so initially determined Intervals of the pastry groups can work in the lay-up pattern. The belt section is adjusted if necessary by placing the biscuits in several rows per track and the trays S are placed closer to the belt conveyor according to the shortened belt section X _W , which is indicated in FIG. 2 by the designation S +. With these new values, the calculation loop of the distances is carried out until suitable values are found for the operation of the inserts E, symbolized by the designation E corresponds to X. The distances X [i] are basically to be kept smaller than the one known in advance Work area of a depositor.

The control unit adjusts the belt speed V _{B of} the belt conveyor in accordance with the intended lay-on pattern. The following ratio can be given approximately: V B = Power × belt section X W Number of shells ,

However, the belt speed also depends on the number of inserts used, which, depending on their performance and the intended sorting task, can be determined approximately by the number of pieces of luggage to be handled, multiplied by the performance and divided by the speed of the inserts: Number of inserts = Σ n ( i ) × power depositors speed

Taking these two relationships into account is one Determination of the belt speed via the number of intended Insert possible.

After the belt speed V _B and the number of inserts n (E) used in accordance with FIG. 2 have been calculated, the control unit determines the suitable number of inserts from the intended lay-up pattern to ensure an optimal overall sorting process. First, the lay-on pattern determined as optimal for the depositors is checked and the group spacings of the items of luggage previously provided in the lay-up pattern are set to the value achievable with the available performance of the lay-ons. Possible variants of the lay-on pattern M are checked for their functionality in connection with the lay-ons, in particular the variant with multi-row lay-on of the biscuits or the groups being arranged in several storage positions on the belt conveyor. As soon as the control unit determines that the tested placement pattern M is not sufficient, a new variant, ie new distances between the pastries, is checked. The corrected lay-up pattern is then checked with regard to the operability of the insert. If it is found in this checking step E = X _opt that the distances X _opt optimized for the feeder A are not suitable for the greatest possible utilization of the feeder, further placement variants M _{V are} checked. 2, each further available support variant V is checked and - if no further variant is available - the number of used supports A + is increased. Accordingly, the distances that are characteristic of the lay-up pattern and significantly influence the coordination of the sorting robots are checked alternately on the part of the lay-up and the lay-in, so that the lay-in and the lay-up are coordinated.

Taking into account the work area AR of each trailer and the number of tasks for the trailer, the determined group _distance X _opt can be approximately determined using the following equation: AR ≥ X opt + X RL + [( task number -1) x 2 S × V B ] the reaction time of the trailer is assumed to be 2 seconds. If the placement of the biscuits with the optimal group distances X ₁ , X ₂ , X ₃ cannot be carried out satisfactorily, the maximum possible distance from the control unit is calculated. If one of the toppers takes on two tasks, ie two types of biscuits are handled by this topper, only the task that has two storage positions is considered. If the same number of storage positions, ie assortment bins, are provided for both sorting tasks, the storage position is considered with the larger group distance and the maximum possible distance calculated in this regard. With these distances, the laying pattern to be specified results with the maximum possible distance between the groups according to the following formulas: X max1 = X OPT (X OPT + X RL + [( Aufgabenzahl- 1) × (2nd S × V B ) AR ) X max2 = 2 × X OPT -X max1

After completing the verification of the determined distances, the group distances X _{OPT are} now used to distribute the sorting tasks to the available depositors, taking into account the required insertion movements of the handling devices, which are the quotient of the total number of pastries to be sorted per assortment and the Results in the number of inserts available for sorting, the lay-up pattern and the assignment of the sorting tasks to the inserts can be coordinated.

An advantageous lay-up pattern is shown in FIG. 4, an optimal utilization of the handling devices used as inserts being achieved with a two-row rest of the biscuits in the respective tracks and the even distribution of four robot movements R ₁ to R ₄ shown.

With the method according to the invention, objects can be different Sorted and sorted into assortments can be automated, for example Pastry types in a given number in one Containers or a bowl are sorted in which the Pastries are distributed. Toys can also be used or handicraft sets in the appropriate assortments or other food products that consist of individual components. For example, with the method according to the invention the various side dishes in a mechanical food production, z. B. grouped hamburgers and ready to manufacture Product can be put together.

Another advantage is that additional detection devices 11a can be arranged between the inserts, which monitor the insertion result. Is z. B. recognized in front of the insert E ₄ that z. B. an object is missing in the assortment, the object can be topped up by insert E ₄ . The scrap of assortment trays can thus be significantly reduced.

Claims (15)

Method for the automated sorting of objects and the compilation of assortments with objects (0, 3) according to a predeterminable sorting rule, the objects (0, 3) being placed from a supply (12) on a belt conveyor (2) and continuously in the work area of controllable handling devices used as inserts (E ₁ , E ₂ , E ₃ , E ₄ ) are conveyed where they are gripped by an insert (E ₁ , E ₂ , E ₃ , E ₄ ) and aligned in an assortment position provided according to the sorting instructions which is assigned to the respective object (0, 3) by a control unit (10), each object (0, 3) being used as a trailer (E ₁ , E ₂ , E ₃ , E ₄ ) A ₁ A ₂ ) used handling device is placed in an intermediate layer close to the intended assortment position on the belt conveyor (2). Method according to claim 1,
characterized in that the objects (0, 3) are placed on the belt conveyor (2) in an arrangement similar to the order state in the supply (12), the support (A ₁ , A ₂ ) placing the objects (0, 3) on the supply taken in groups. The method of claim 1 or 2,
characterized in that the objects (0, 3) of an object type (I, II, III) with the higher number of pieces per assortment per assortment are placed closer to the sorting position on the belt conveyor (2) than the objects (0,3 ) of the other object types (I, II, III). Method according to one of claims 1 to 3,
characterized in that all the feeders (A ₁ , A ₂ ) and the subordinate inserts (E ₁ , E ₂ , E ₃ , E ₄ ) are controlled by the control unit (19) in a coordinated manner taking into account their respective handling performance. Method according to one of claims 1 to 4,
characterized in that the objects (0, 3) are placed in tracks (Sp) of the same object type (I, II, III) in the conveying direction (5) of the belt conveyor (2). Method according to one of claims 1 to 5,
characterized in that each support (A _1-4 ) places the objects (0, 3) of the same type (I, II, III) simultaneously in the intended track (Sp) and the distances (X (1), X (2) , X (3)) between the placed groups (E) placed objects are uniform. Method according to one of claims 1 to 6,
characterized in that an optical recognition device (11) arranged between the supports (A ₁ , A ₂ ) and inserts (E ₁ , E ₂ , E ₃ , E ₄ ) of each of the objects (0,3) passing through on the belt conveyor (2) detected at least with regard to the actual position and the control unit (10) is supplied with a corresponding signal (13) and the control unit (10) controls the inserts (E ₁ , E ₂ , E ₃ , E ₄ ) on the basis of the signal (13) corrected. Method according to claim 7,
characterized in that the control unit (10) determines the orientation of the objects (0,3) from the signal (13) of the detection device (11). Method according to claim 7 or 8,
characterized in that the control unit (10) identifies objects (0, 3) deviating from the target condition on the basis of the signal (13) from the detection device (11) and excludes them from the sorting into the assortment position. Method according to one of claims 1 to 9,
characterized in that the objects (0, 3) are placed on the belt conveyor (2) in a periodically recurring placement pattern (M). Method according to one of claims 1 to 10,
characterized in that the assortment positions for depositing the objects are provided essentially parallel to the tracks (Sp) of the objects (0, 3) on the belt conveyor (2). Method according to one of claims 1 to 11,
characterized in that the objects (0, 3) are deposited near a container (4, S) which is placed on the belt conveyor (2) at the intended assortment positions, the container distances being changeable in the running direction of the belt conveyor (2). Method according to one of claims 1 to 12,
characterized in that the objects (0, 3) are sorted according to the number of pieces of the same type per assortment. Method according to one of claims 1 to 13,
characterized in that the control unit (10) adjusts the belt speed (V _B ) of the belt conveyor (2) depending on the performance of the inserts (E ₁ , E ₂ , E ₃ , E ₄ ) as a function of an intended lay-on pattern (M). Method according to one of claims 1 to 14,
characterized in that the control unit (10) by varying possible lay-on patterns (M _V ), the belt speed (V _B ) of the belt conveyor (2), the distance between the containers (4) and the number of handling devices (A ₁ , A ₂ , E ₁ , E ₂ , E ₃ , E ₄ ) sets the total sorting performance that can be achieved.

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