Sorting processing method and system for platesTechnical Field
The embodiment of the invention relates to the field of plate processing, in particular to a plate sorting method and a plate sorting system.
Background
In the furniture production industry in the prior art, batch operation is adopted, different types of plates are classified, then the plates are arranged for corresponding procedures to be processed, each procedure only carries out the same processing treatment on the same type of plates in the same time period, finally, the processed plates of various types are sorted and combined, and the processed plates belonging to the same furniture are put together to be packaged. In the process of processing production in the prior art, identification is not needed for each plate, and the same type of plate can be processed in batches.
In the process of implementing the invention, the inventor finds that the prior art has at least the following defects:
with the development of the industry 4.0, customized furniture is more and more in demand, and a furniture manufacturer does not need to design a piece of furniture, then carry out batch production and then sell the furniture. In the face of the demand of customized furniture, different types of plates need to be prepared and combined in advance, more than one type of processing treatment is carried out on the different types of plates in the same procedure, then the various processed plates are sorted, and the processed plates belonging to the same furniture are combined and packaged. In order to meet the requirement, in the prior art, when the processed plates are sorted and packed, the plates processed in batches are sorted, and whether small plates belong to the same part or not is not required to be judged, in other words, no applicable processing scheme is provided for sorting and packing customized furniture plates. Meanwhile, in the prior art, when the processed plates are sorted and packed, the plates are stored at fixed positions according to the batches to which the plates belong, and then the stored plates are manually combined and packed, namely, the storage of the plates and the combination of the plates are two separated processing stages in time and need to be completed by means of manual processing, so that the sorting efficiency is low.
Disclosure of Invention
The embodiment of the invention provides a plate sorting processing method and a plate sorting processing system, which are suitable for sorting and combining requirements aiming at customized furniture plates. Meanwhile, in the sorting treatment process, the process of storing the plates and combining the plates is synchronously completed, so that the sorting efficiency is improved.
In order to achieve the above object, an embodiment of the present invention provides a method for processing a plate, including: carrying out image recognition on a label of a plate to obtain plate label information on the plate; performing matching retrieval in a part information base according to the plate label information to obtain part information to which the plate belongs, wherein the part information base stores a plurality of pieces of part information to which the plate corresponding to the plate label information belongs; sorting the plates through a sorting channel, storing the plates into a warehouse, monitoring and recording the storage state of the plates, wherein a plate transferring device for transferring the plates is arranged in the sorting channel; the monitoring record at least comprises: the stored plate label information, the part information and the storage position information of the plate; and if the monitoring record shows that the assembled plates belonging to the same part exist in the warehouse, the assembled plates are assembled and output through the sorting channel.
An embodiment of the present invention further provides a system for processing a plate, including: the system comprises image identification equipment, a background server, a sorting channel and a warehouse, wherein a plate transfer device for transferring plates is arranged in the sorting channel, the server is respectively connected with the image identification equipment and the plate transfer device, and a part information base, a matching retrieval module, a plate storage module, a monitoring recording module and a plate output module are arranged in the server; the image recognition equipment is used for carrying out image recognition on the label of the plate to obtain plate label information on the plate; the matching retrieval module is used for performing matching retrieval in a part information base according to the plate label information to acquire part information to which the plate belongs, and the part information base stores a plurality of pieces of part information to which the plate corresponding to the plate label information belongs; the plate storage module is used for controlling the plate transfer device to sort the plates through the sorting channel and store the plates into a warehouse; the monitoring record module is used for monitoring and recording the storage state of the plate stored in the warehouse, and the monitoring record at least comprises: the stored plate label information, the part information and the storage position information of the plate; and the plate output module is used for monitoring the monitoring records, and controlling the plate transfer device to output the combined plates through the sorting channel in a combined manner if the monitoring records show that the plates of the same part are combined in the warehouse.
According to the processing method and the processing system for the sheet material, disclosed by the embodiment of the invention, the image identification is carried out on the sheet material label, and the identified label information is matched with the part stored in the part information base to determine the part to which the sheet material belongs; then, sorting the plates through a sorting channel and storing the plates into a warehouse, and monitoring the storage state of the plates; when the assembled plates belonging to the same part exist in the warehouse, the plates are assembled and output through the sorting channel. Therefore, when the plates belonging to the same part are sorted and combined, the two processes of sorting, storing and combined outputting are synchronously realized, and the plate sorting efficiency is improved.
The foregoing description is only an overview of the technical solutions of the present invention, and the embodiments of the present invention are described below in order to make the technical means of the present invention more clearly understood and to make the above and other objects, features, and advantages of the present invention more clearly understandable.
Drawings
Fig. 1 is a flowchart of a method for sorting and processing a sheet according to an embodiment of the present invention;
fig. 2 is a sheet material form diagram provided with a sheet material label according to an embodiment of the present invention;
fig. 3 is a flowchart of another method for sorting and processing the sheet material according to the embodiment of the present invention;
fig. 4 is a schematic layout view of a sorting area for sheets according to an embodiment of the present invention;
fig. 5 is a schematic diagram of a process for selecting a sorting channel according to an embodiment of the present invention;
fig. 6 is a first schematic structural diagram of a sorting channel according to an embodiment of the present invention;
fig. 7 is a schematic structural diagram of a sorting passage according to an embodiment of the present invention;
FIG. 8 is a schematic structural diagram of an exit transport zone provided in accordance with an embodiment of the present invention;
FIG. 9 is a schematic view of a process for synchronously outputting a sheet material in an outlet conveying area according to an embodiment of the present invention;
FIG. 10 is a second schematic view of the process of synchronously outputting the boards in the outlet conveying area according to the embodiment of the present invention;
fig. 11 is a schematic structural diagram of a sorting system for sheet materials according to an embodiment of the present invention;
fig. 12 is a schematic structural diagram of a plate storage module according to an embodiment of the present invention.
Detailed Description
Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.
Example one
Fig. 1 is a flowchart of a method for sorting and processing a sheet according to an embodiment of the present invention, where an execution main body of the method may be a system having functions of image recognition, data information retrieval and matching, and industrial control, and the system is applied to a furniture sheet processing line for sorting and processing a sheet. As shown in fig. 1, the method for sorting and processing the plate materials comprises the following steps:
and S110, carrying out image recognition on the label of the plate to obtain the label information of the plate on the plate.
The plate labels are arranged on the surfaces of the plates and are used for uniquely identifying the symbol marks of the plates. In order to rapidly identify each plate in the plate processing process, after a large plate is cut in the initial stage of plate processing, a system sets a plate label on each small plate formed after cutting.
Here, the large-sized plate material according to the present invention refers to a monolithic plate material for the cutting process; the small plate is a local single plate corresponding to each cutting area after cutting. The sheet material provided with the sheet material label in the present embodiment may be, but is not limited to, a small sheet material formed after cutting.
Each sheet tag corresponds to a standard type of sheet in the sheet information library. As shown in table 1, a sample of the standard plate material information stored in the plate material information library is shown. The plate information base is pre-stored with a plurality of pieces of standard plate information, and each piece of standard plate information is used for describing relevant information of one standard type plate, such as one or more pieces of information in graphs, surface patterns, materials, thicknesses and processing procedure information aiming at the standard type plate. The contents of the information of each standard plate are not completely the same.
In table 1, each piece of standard plate material information at least includes graphic information, i.e. shape, of the standard type plate material: such as triangular, rectangular, and corresponding dimensions: information such as T2x2x3 (triangle having sides of 2m, and 3m, respectively, and T represents a triangle), R5x3 (rectangle having a length of 5m and a width of 3m, and R represents a rectangle), and R3x4 (rectangle having a length of 5m and a width of 3m, and R represents a rectangle) (in table 1, the standard plate material information other than the graphic information is omitted from the standard plate material information).
TABLE 1 Panel information base
| Numbering | Standard sheet material information |
| 1 | Triangle, T2x2x3, … … … … … … |
| 2 | Rectangle, R5x3, … … … … … … …. |
| 3 | Rectangle, R3x4, … … … … … … …. |
| …. | …………………. |
In the initial stage of plate processing, the system assigns a unique plate identifier to each plate to be processed, and stores the plate identifier in association with the standard plate information to which the plate belongs, so as to form an information storage unit shown in table 2:
table 2 plate identification and standard plate information association storage table
| Numbering | Panel sign | Standard sheet material information |
| 1 | ID001 | Triangle, T2x2x3, … … … … … … …. |
| 2 | ID002 | Rectangle, R5x3, … … … … … … …. |
| 3 | ID003 | Rectangle, R3x4, … … … … … … …. |
| …. | …. | …………………. |
The plate identifier is an identifier assigned to each plate, and the identifier may be an identifier without any meaning, as long as the uniqueness of each plate is ensured.
The plate label in this embodiment may be a plate label generated according to the plate identifier. Specifically, the content of the plate label generated according to the plate identifier may be the plate identifier itself, or may be a two-dimensional code or other symbol identifier generated according to the plate identifier and/or standard plate information corresponding to the plate identifier.
Fig. 2 is a form view of a plate material provided with a plate material label.
When various working procedures are carried out on the plates, the plate label information of each plate is obtained through image recognition, then the standard plate information corresponding to the plates is obtained through the query table 2 according to the plate label information, and then the corresponding working procedures are carried out on the plates.
The plate sorting system shown in the embodiment can be used for sorting plates provided with plate labels. For example, in one specific application scenario shown, the board sorting processing system may sort and combine all the boards that have completed the processing procedure according to the parts to which the boards belong, so as to combine and output the boards belonging to the same part (e.g., a table, a cabinet, and a chair, which may each be regarded as a part) for packing by workers.
Specifically, when the plate is sorted according to the part to which the plate belongs, after the plate completes all processing procedures, the system performs image recognition on the label of the plate to obtain the plate label information on the plate, so that the standard plate information corresponding to the plate can be obtained.
S120, performing matching retrieval in a part information base according to the plate label information to obtain part information to which the plate belongs; the part information base stores a plurality of pieces of part information to which the plate corresponding to the plate label information belongs.
The plate information base can be arranged in a background server with data storage and information retrieval functions. After the image identification device identifies and acquires the plate label information on the plate, the plate label information can be sent to the server, so that the server performs matching retrieval in the part information base according to the plate label information to acquire the part information corresponding to the plate.
As shown in table 3, the part information is a sample of the part information stored in the part information library. The component information base stores a plurality of pieces of component information to which the plate material corresponding to the plate material label information belongs in advance. In table 3, the plate material identification corresponding to the plate material label and the part information to which the plate material belongs are stored in association with each other. And the part information of the plate can be inquired through the plate identification corresponding to the plate label. Optionally, the part information base further includes standard plate information corresponding to each plate identifier.
TABLE 3 parts information base
| Numbering | Panel sign | Standard sheet material information | All the related parts |
| 1 | ID001 | Triangle, T2x2x3, … … … … … | Component 1 |
| 2 | ID002 | Rectangular, R5x3, … … … … … | Component 2 |
| 3 | ID003 | Rectangle, R3x4, … … … … …. | Component 3 |
| …. | …. | …………………. | ………… |
S130, sorting the plates through the sorting channel, storing the plates into a warehouse, and monitoring and recording the storage state of the plates; the sorting channel is internally provided with a plate transferring device for transferring plates; the monitoring record at least comprises: stored plate label information, belonging part information and storage position information.
In order to synchronously perform the buffer storage and the combined output of the plates, the present embodiment is provided with a sorting channel and a warehouse for matching the sorting process of the plates. The sorting channel is a passage for conveying the plates, and the plates are sorted and stored in the warehouse when being conveyed on the sorting channel; meanwhile, the sorting channel can also receive the plate taken down from the warehouse and transmit and output the plate to the execution position of the next process. The plate transferring device for transferring the plates is arranged in the sorting channel, can be a vehicle inserting device, a sucker hand and the like, and can realize the transferring operation of the plates between the warehouse and the sorting channel.
Specifically, after determining the information of the part to which the plate belongs, the server allocates the storage positions of the plate in the warehouse, then conveys the plate through the corresponding sorting channels, controls the plate transfer device to sort and store the plate into the warehouse, and monitors and records the storage state of the plate. In the server, a monitoring data table of the storage state of the plate is preset, and the data table is used for dynamically recording the information of the plate stored in the warehouse in real time, such as plate label information, plate identification, standard plate information, belonging part information and storage position information. As shown in Table 4, a sample monitoring data table is stored for the sheet material.
Table 4 sheet storage monitoring data table
| Numbering | Panel sign | Standard sheet material information | Storage location |
| 1 | ID001 | Triangle, T2x2x3, … … … … … | Warehouse 1, first floor, 3.3 |
| 2 | ID002 | Rectangular, R5x3, … … … … … | Warehouse 2, three-layer, 4.0 |
| 3 | ID003 | Rectangle, R3x4, … … … … …. | Warehouse 2, first floor, 1.5 |
| …. | …. | …………………. | ………… |
When the plates are actually stored, the storage positions of the plates in the warehouse are randomly distributed, and each type of standard plate has no fixed storage position. When a new plate needs to be stored, the server can roughly judge the storage space of the plate according to the information of the current plate, and then allocate an idle storage position to the plate according to the current plate storage monitoring data table. After the allocation is complete, a new information storage location is created in the data table, such as table 4. The information storage unit comprises plate identification of the plate (because the plate identification and the plate label are in one-to-one correspondence, the plate label information can be replaced by the plate identification in the server during actual recording), standard plate information and information of a storage position. The storage location information includes a stored warehouse number, a layer location (a multi-layer storage location for a stereoscopic warehouse), and a distance (m) from a start point of each layer, and includes, for example: the storage positions corresponding to warehouse 1, one floor and 3.3 are the first floor of warehouse No. 1, and are 3.3m away from the starting point (one end of the warehouse) of the floor.
And S140, if the monitoring records show that the assembled plates belonging to the same part exist in the warehouse, the assembled plates are combined and output through the sorting channel.
And in the process of storing the plates into the warehouse, the server also monitors the monitoring records of the stored plates in real time, and if the monitoring records show that the assembled plates belonging to the same part exist in the warehouse, the assembled plates are transferred to the sorting channel and are combined and output through the sorting channel. By "assembled" sheets is meant that the warehouse currently stores a complete set of sheets needed to form a part, which may be stored in a distributed manner at various locations in the warehouse.
After the server controls the plate transfer device to output the plates, the server deletes the contents stored in the monitoring records of the corresponding plates.
The plate sorting processing method of the embodiment of the invention identifies the image of the plate label and matches the identified label information with the part stored in the part information base to determine the part to which the plate belongs; then, sorting the plates through a sorting channel and storing the plates into a warehouse, and monitoring the storage state of the plates; when the assembled plates belonging to the same part exist in the warehouse, the plates are assembled and output through the sorting channel. Therefore, when the plates belonging to the same part are sorted and combined, the two processes of sorting, storing and combined outputting are synchronously realized, and the plate sorting efficiency is improved.
Example two
Fig. 3 is a flowchart of another method of a sorting method for sheet materials according to an embodiment of the present invention, which can be regarded as a specific implementation manner of the method embodiment shown in fig. 1. In this embodiment, the sorting of the sheet material is performed in the sorting zone. The following is a brief description of the sorting zones:
as shown in fig. 4, the sorting zone includes an inlet transfer zone, a sorting performance zone, and an outlet transfer zone. The inlet conveying area is used for receiving plates to be sorted, such as plates which have completed all processing procedures, and has the main functions of conveying the plates and enabling the plates to pass through the inlet of each sorting channel; a sorting execution area including a plurality of sorting channels (the same as the sorting channels mentioned in the first embodiment) and warehouses located at both sides of the sorting channels; the two tasks are mainly completed on each sorting channel, namely, the plate which just enters the sorting channel is stored in a warehouse, the plate which belongs to the same part and is combined in the warehouse is taken out of the warehouse, and the plate is output to an outlet conveying area through the sorting channel; and the outlet conveying area is used for receiving the plate materials which are output from the sorting channel and belong to the same part, and outputting the plate materials to the tail end of the outlet conveying area for packing by workers. The inlet conveying area, the sorting channel and the outlet conveying area are provided with conveying platforms built by conveyor belts, conveying rollers and the like for directionally conveying the plates.
In fig. 4, a plurality of sorting channels are provided in the sorting execution area, and plate storage areas are provided corresponding to the sorting channels, and the plate storage areas jointly form a warehouse.
A first transfer device (not shown) may also be provided at the inlet of each sorting channel. The first transfer device may transfer the sheet material from the entrance conveying area to the sorting channels as the entrance conveying area conveys the sheet material and passes the sheet material through the entrance of each sorting channel.
A second transfer device (not shown) can also be provided at the outlet of each sorting channel. The second transfer device can transfer the sheet material from the sorting channel to the exit conveying area.
Further, as shown in fig. 5, at the entrance of the entrance transfer area corresponding to each sorting channel, a first blocking mechanism may be provided to block the passage of the sheet material, and the first blocking mechanism may be controlled by the server to intermittently block the sheet material from continuing to be transferred at the entrance transfer area, thereby assisting the first transfer device to prevent the sheet material from being transferred at the entrance transfer area until the first transfer device does not transfer the sheet material to the specific sorting channel.
On the basis, the plate sorting processing method shown in the embodiment comprises the following steps:
and S310, carrying out image recognition on the label of the plate to obtain the label information of the plate on the plate. Step S310 is similar to step S110.
Specifically, as shown in fig. 5, an image recognition device may be provided at an entrance of the entrance transfer area, and the image recognition device is connected to a server. When the plates sequentially enter the import conveying area, the image recognition equipment scans the plate labels on the plates to acquire corresponding plate label information, and then the plate label information is transmitted to the server.
S320, performing matching retrieval in the part information base according to the plate label information to obtain part information to which the plate belongs; the part information base stores a plurality of pieces of part information to which the plate material corresponding to the plate material label information belongs. Step S320 is the same as step S120.
S330, selecting one sorting channel from the plurality of sorting channels according to a preset strategy, and conveying the plate material to the selected sorting channel.
Wherein the predetermined strategies include, but are not limited to, the following three:
and the first strategy is to select the sorting channel with the minimum sorting pressure load as the selected sorting channel according to the sorting pressure loads of the current sorting channels.
The sorting pressure load of each sorting channel mainly refers to the busy and idle states of the plate transferring devices in the sorting channels for executing sorting operation. The more frequent the sorting operation, the greater the corresponding sorting pressure load and vice versa. When the sorting pressure load of each sorting channel is specifically evaluated, the evaluation can be carried out by monitoring the action condition of the plate transferring device or monitoring and recording the storage state of the plates and the number of the plates distributed to each sorting channel in the latest time period. The plate material transferring device is operated continuously, or the number of plate materials distributed to the sorting channels is large, the sorting pressure load of the corresponding sorting channel is larger, and the sorting pressure load is smaller.
And a second strategy is that according to the current monitoring record, the sorting channel corresponding to the plate storage area with the largest idle storage area is selected as the selected sorting channel.
After the plates are sorted by the different sorting channels, the plates can be stored in the plate storage areas corresponding to the sorting channels by the plate transfer device. Thus, the selection of which sheet storage area to store the current sheet directly affects which sort lane the sheet needs to pass through. In order to uniformly utilize the storage area of each plate storage area, when the sorting channel is selected, the sorting channel corresponding to the plate storage area with the largest idle storage area is selected as the selected sorting channel by inquiring the monitoring record stored in the current plate, so that the storage quantity balance of the plate in each plate storage area is ensured.
Extracting stored plate storage area information of other plates of the same part to which the plate belongs according to the current monitoring record; and selecting the sorting channel corresponding to the plate storage area of all the plates which are closest to the same part to which the assembly belongs as the selected sorting channel.
In order to output all the plates belonging to the same part synchronously through the same sorting channel or the sorting channels with the similar positions as much as possible, when the sorting channel is selected, the sorting channel corresponding to the plate storage area closest to the plate collecting all the plates belonging to the same part is selected as much as possible (in the embodiment, the two closest sorting channels have the closest plate storage areas). For example: aiming at a part, 3 plates contained by the part are stored in a first plate storage area, 1 plate contained by the part is stored in a second plate storage area (the positions of the first plate storage area and the second plate storage area are close to each other), when the plate to be stored at present is judged to belong to the part, the plate is preferentially stored in the first plate storage area or the second plate storage area, and if the areas of the idle storage areas of the first plate storage area and the second plate storage area are insufficient, the plate storage areas close to the positions of the two plate storage areas are selected to store the plate. Correspondingly, the sorting channel corresponding to the plate storage area is selected as the selected sorting channel. Therefore, all the plates contained in the same part can be combined and output in space as far as possible, and workers can pack the plates conveniently.
When the sorting channel corresponding to the plate is specifically selected, priority levels can be set for the three strategies in advance, and a proper sorting channel can be selected according to the priority levels. For example, when sorting channels are selected according to all the preset strategies, at least two sorting channels meeting the requirements exist, and the sorting channel selected according to the strategy with the highest priority level is selected as the selected sorting channel.
Specifically, after the sorting channel corresponding to the sheet material is selected, the server communicates with the first transfer device and the first baffle mechanism at the corresponding sorting channel, instructs the first baffle mechanism to fall down when the sheet material is close to the inlet of the sorting channel, so as to prevent the sheet material from being transferred continuously, and instructs the first transfer device to transfer the sheet material from the inlet transfer area to the sorting channel. After the sheet material is transferred to the sorting channel, the first flap mechanism is instructed to lift to allow subsequent sheet materials on the entrance conveying area to continue to be conveyed.
S340, after the plates are sorted by the selected sorting channel, the plates are stored in a plate storage area corresponding to the selected sorting channel, and a plate transfer device for transferring the plates is arranged in the sorting channel.
Because each sorting channel has two functions of sorting, storing and outputting the plates, the conveying platform of the sorting channel is also correspondingly divided into a storage buffer part and an output part, and the two parts have the same conveying direction and are always in a running state. The storage buffer part can be used for receiving the plates from the inlet conveying area, and the plates are taken away by the plate transfer device in the storage buffer part and stored in the warehouse; the output part can be used for outputting the assembled plates, and when a complete plate assembly of a certain part exists in the warehouse, the server controls the plate transfer device to take the plates out of the warehouse and place the plates on the conveying platform of the output part so as to output the plates to the outlet conveying area.
As shown in fig. 6, in order to separate the functions of the storage buffer part and the output part on the sorting passage, the conveying platforms of the two parts can be independently and separately arranged to form two mutually separated conveying passages; (ii) a Alternatively, as shown in fig. 7, the two-part transfer platform may be implemented as a single complete transfer platform, i.e. using a continuous length of transfer path, and the two parts may be separated by the provision of a second shutter mechanism. The second baffle mechanism is controlled by the server and intermittently separates the plates from moving from the storage buffer area to the output area.
Preferably, the length of the storage buffer part of the transfer platform in fig. 7 may be set to 5.5m, and the length of the output part may be set to 2.5 m. A second stop mechanism may be provided between the two-section transfer platform for preventing sheets to be stored from jumping over the storage buffer section into the output section without being stored.
Taking the structure of the sorting channel shown in fig. 7 as an example, after the server selects the sorting channel corresponding to the sheet material, the server controls the first transfer device to transfer the sheet material onto the sorting channel, and the second shutter mechanism is in a falling state to prevent the sheet material to be stored from jumping over the storage buffer portion to the output portion without being stored.
The steps S330 to S340 may be regarded as a refining step of sorting the plate material through the sorting passage and storing the plate material in the warehouse.
S350, monitoring and recording the storage status of the plate stored in the warehouse, where the monitoring and recording at least includes: the stored plate material label information, the belonging part information and the storage position information of the plate material. Step S350 is the same as the step of monitoring and recording the storage state of the stored plate material in step S130.
And S360, if the monitoring records show that the assembled plates belonging to the same part exist in the warehouse, the assembled plates are combined and output through the sorting channel. Step S360 is similar to step S140.
Specifically, the combined output of the assembled plates in the warehouse through the sorting channel can be divided into two cases, which are respectively:
and if the combined plates are stored in the plate storage areas corresponding to the same sorting channel, outputting the plates when the sorting pressure load of the corresponding sorting channel is smaller than a preset value.
The sorting pressure load value can be set according to the number of the plates to be sorted and stored on the current sorting channel and/or the busy and idle states of the current plate transferring device. For example, the larger the number of sheets to be sorted and stored on the sorting pass, the more busy the sheet transfer device is in operation, and the larger the corresponding sorting pressure load value.
Specifically, the server periodically monitors the sorting pressure load of each sorting channel, when the combined plates are stored in the plate storage areas corresponding to the same sorting channel, the server can only pay attention to the sorting pressure load value of the sorting channel, and when the sorting pressure load of the sorting channel is smaller than a preset value, the server can control the plate transfer device to output the combined plates through the sorting channel at a proper time.
And if the combined plates are stored in the plate storage areas corresponding to different sorting channels, outputting the plates when the sorting pressure loads corresponding to all the sorting channels are smaller than the preset value.
Specifically, the server periodically monitors the sorting pressure loads of the sorting channels, and when the combined plate is stored in the plate storage areas corresponding to different sorting channels, the server can only pay attention to the sorting pressure load values of the sorting channels. When the sorting pressure loads of the sorting channels are smaller than the preset value, the server can control the plate transferring device to output the combined plates through the sorting channels at proper time.
Taking the structure of the sorting channel shown in fig. 7 as an example, when the server determines that the combined plate exists in the plate storage area corresponding to the current sorting channel, the server selects a time period when the sorting pressure load of the current sorting channel is smaller than the preset value, and controls the plate transfer device to take out the plates from the warehouse and sequentially place the plates to the output part of the conveying platform for plate output. When the actual plates are output, the combined plates can be placed at the position close to the second baffle mechanism in the storage buffer part, the second baffle mechanism is in a falling state at the moment, and after all the plates to be output are stacked, the second baffle mechanism is lifted so that all the plates can be output together.
Next, the present embodiment will explain the sorting process of the plate material in detail from the time sequence control:
1. control of overall timing
Theoretically, on the whole conveying path from the inlet conveying area to the outlet conveying area, one plate enters every 10 seconds, one plate is output every 10 seconds, the operation lasts for 10 hours a day, the inlet and the outlet of 3600 plates can be processed, and the capacity requirement of a production line is met. At present, the plate transferring device goes back and forth one by one and takes 18 seconds to the utmost by taking, placing and reversing the plate. If path optimization is possible to reach around 16 seconds, 14 seconds of round trip should be reached in conjunction with the average path calculation. Therefore, it is estimated that a sheet material is taken and placed by the sheet material transfer device for 14 seconds, and the simultaneous taking of the sheet materials by the 4 sheet material transfer devices (corresponding to the 4 sorting passes) can sufficiently cope with the peak speed of a sheet material of 14/4 seconds, which can last for a certain time, and does not affect the receiving of a new sheet material from the inlet conveying area, but affects the subsequent sheet material output. Considering that there is a 5.5m transfer platform in each sorting pass as a storage buffer, theoretically one sheet can be faster than 3.5 seconds, but the duration is limited, if the transfer platform storing the buffer is full, there will be no place to store when a new sheet enters, and it can be considered to lengthen the length of the transfer platform to buffer.
2. How to advance
When a plate enters a sorting area, plate label information is acquired through an image recognition device, then relevant information (standard type plate information and belonging part information corresponding to the plate) of the plate is obtained through retrieval of the plate label information by a server, a sorting channel where the plate is suitable for sorting is calculated according to monitoring records stored in the plate in a current warehouse, a principle of proximity is adopted, sorting load of each sorting channel, free area of each plate storage area and storage conditions of other plates of the same part are considered, and the plate is placed in a suitable plate storage area. Considering the synchronous output of the sheet materials belonging to the same part, the length of the sheet materials output at one time by one sorting channel is considered. Preferably, the sheet materials of the same part which do not exceed the length of the output part conveying platform in fig. 6 or fig. 7 are stored in the sheet material storage areas corresponding to the same sorting channel, the rest sheet materials can be stored in the sheet material storage areas corresponding to the next sorting channel, and so on, so that all the sheet materials of the same part can be synchronously output by each sorting channel.
How to go out
As shown in fig. 8, the width of the conveying platform of the outlet conveying area is set to be not less than the minimum width required for one-time sheet output, such as 2.4m in fig. 10, based on the length of the conveying platform of the output portion of each sorting passage, which is set to be 2.5m in fig. 7 (the actual length can be arbitrarily selected according to the sheet output). For example, when a certain sorting channel outputs all the boards contained in one part and the total output length of the boards is not more than 2.4m, the boards can be taken out from the warehouse by the board transfer device for multiple times and placed on the conveying platform of the output part of the sorting channel, then the boards are transferred to the corresponding outlet conveying area with the width of 2.4m by the second conveying transfer device arranged at the outlet of the sorting channel, and after all the boards are placed, the conveying platform of the outlet conveying area is started to output all the boards at one time. As shown in fig. 9, the outlet transport area is shown enlarged for explaining the plate material feeding method, and for example, if 4 plate materials belonging to the same component are arranged in total, the 4 plate materials may be arranged side by side on the outlet transport area and then fed in the horizontal direction. As another alternative to the output method, as shown in fig. 10, during the output process of the boards, the boards are conveyed on the conveying platform of the output part in a longitudinal row (4 boards in the figure belong to the same part, but are output in two rows), and when the boards are transferred to the outlet conveying area by the second conveying transfer device, the boards are conveyed in a row along the conveying direction of the outlet conveying area. When the plates to be output are output from the sorting channels, the plates are arranged in a plurality of rows on the outlet conveying area correspondingly, and the arrangement can also facilitate workers to separately identify small plates of each product.
When the plate output length corresponding to one part is larger, the plates of the same part can be synchronously output through a plurality of sorting channels. And the selection of the output time is carried out when the sorting pressure load of each sorting channel is smaller than the preset load. Examples are as follows:
assuming that 4 sorting channels exist in the sorting execution area to sort and output the plate, the output platelet data of each sorting channel is as follows:
wherein the length of the corresponding plate is arranged in the "()", the "|" is used for separating plates from different batches, and the d-type plate is output independently.
The sheet output sequence and sheet output for the 4 sorting passes are as follows:
1: b0 and b1 of the 2 nd channel are output once;
2: c0 and c1 of the 3 rd channel are output once;
3: a1 of the 0 th channel, a0, a4 of the 1 st channel, a5, a6 and a8 of the third channel are output together;
4: channel 2 a7 output alone
5: and d, outputting the small plates of the pack in sequence.
The plate sorting method provided by the embodiment of the invention is based on the method embodiment shown in figure 1: firstly, sorting plates through a plurality of sorting channels, and selecting one sorting channel as a sorting channel corresponding to the current plate according to the sorting pressure load of each sorting channel, the free storage area of a plate storage area and the stored information of the plate storage area where other plates of the same part belong to the plate are located, so as to sort and store the plates most efficiently while coordinating the sorting pressure load of each sorting channel; secondly, when the plates are synchronously output, the sorting pressure load of the corresponding sorting channel is also considered, so that the plates are synchronously output on the premise of not influencing the buffer storage of the plates.
EXAMPLE III
Fig. 11 is a schematic structural diagram of a sorting system for sheet materials according to an embodiment of the present invention, which can be used to execute the method steps shown in fig. 1. As shown in fig. 10, the processing system of the plate material includes: the system comprises image recognition equipment 101, a background server 102, a sorting channel and a warehouse, wherein a plate transferring device 103 used for transferring plates is arranged in the sorting channel, and the server 102 is respectively connected with the image recognition equipment 101 and the plate transferring device 103; the server 102 is provided with a component information base 1021, a matching retrieval module 1022, a sheet material storage module 1023, a monitoring recording module 1024 and a sheet material output module 1025; wherein:
the image recognition device 101 is used for performing image recognition on the label of the plate to obtain plate label information on the plate; the matching retrieval module 1022 is configured to perform matching retrieval in the component information library 1021 according to the plate tag information to obtain component information to which the plate belongs, and the component information library 1021 stores a plurality of pieces of component information to which the plate corresponding to the plate tag information belongs; the plate storage module 1023 is used for controlling the plate transfer device 103 to store the plates into a warehouse after the plates are sorted by the sorting channel; the monitoring and recording module 1024 is configured to perform monitoring and recording on the storage state of the plate stored in the warehouse, where the monitoring and recording at least includes: the stored plate label information, the part information and the storage position information of the plate; and the plate output module 1025 is used for monitoring the monitoring records, and controlling the plate transfer device 103 to combine and output the combined plates through the sorting channel if the monitoring records show that the combined plates belonging to the same part exist in the warehouse.
The block diagram of the sorting passage and the warehouse in this embodiment can refer to the corresponding block diagram portions shown in fig. 4 to 10.
The plate sorting processing system of the embodiment of the invention identifies the image of the plate label and matches the identified label information with the part stored in the part information base to determine the part to which the plate belongs; then, sorting the plates through a sorting channel and storing the plates into a warehouse, and monitoring the storage state of the plates; when the assembled plates belonging to the same part exist in the warehouse, the plates are assembled and output through the sorting channel. Therefore, when the plates belonging to the same part are sorted and combined, the two processes of sorting, storing and combined outputting are synchronously realized, and the plate sorting efficiency is improved.
Example four
The embodiment of the present invention further provides another schematic structural diagram of a board sorting processing system, which can be regarded as a detailed structure of the system embodiment shown in fig. 11, and can be used for executing the method steps shown in fig. 3, on the basis of the structure shown in fig. 11, a plurality of sorting channels shown in this embodiment are provided, a board storage area is provided corresponding to each sorting channel, and each board storage area jointly forms a warehouse.
On this basis, as shown in fig. 12, the plate material storage module 1023 specifically includes:
a channel selecting unit 231, configured to select one of the sorting channels according to a preset policy, and control to transfer the sheet material to the selected sorting channel; and the plate storage unit 232 is used for controlling the plate transfer device 103 to store the plate into the plate storage area corresponding to the selected sorting channel after the plate is sorted by the selected sorting channel.
Further, the channel selecting unit 231 is specifically configured to select, according to the sorting pressure loads of the current sorting channels, the sorting channel with the smallest sorting pressure load as the selected sorting channel.
Further, the channel selecting unit 231 is specifically configured to select, according to the current monitoring record, the sorting channel corresponding to the sheet storage area with the largest free storage area as the selected sorting channel.
Further, the channel selecting unit 231 is specifically configured to extract, according to the current monitoring record, stored information of a plate storage area where other plates belonging to the same part as the plate are located; and selecting the sorting channel corresponding to the plate storage area of all the plates which are closest to the same part to which the assembly belongs as the selected sorting channel.
Further, the sheet output module 1025 is specifically configured to control the sheet transfer device 103 to output the sheet when the sorting pressure load of the corresponding sorting channel is smaller than a preset value if the combined sheet is stored in the sheet storage area corresponding to the same sorting channel; or,
if the assembled plates are stored in the plate storage areas corresponding to different sorting channels, when the sorting pressure loads corresponding to all the sorting channels are smaller than the preset value, the plate transfer device 103 is controlled to output the plates.
On the basis of the structural embodiment shown in fig. 11, the plate sorting processing system of the embodiment of the present invention is additionally provided with the module units having the following functions: sorting the plates through a plurality of sorting channels, and selecting one sorting channel as a sorting channel corresponding to the current plate according to the sorting pressure load of each sorting channel, the free storage area of a plate storage area and the stored information of the plate storage area where other plates belonging to the same part of the plate belong to, so as to sort and store the plates most efficiently while coordinating the sorting pressure load of each sorting channel; secondly, when the plates are synchronously output, the sorting pressure load of the corresponding sorting channel is also considered, so that the plates are synchronously output on the premise of not influencing the buffer storage of the plates.
Those of ordinary skill in the art will understand that: all or a portion of the steps of implementing the above-described method embodiments may be performed by hardware associated with program instructions. The program may be stored in a computer-readable storage medium. When executed, the program performs steps comprising the method embodiments described above; and the aforementioned storage medium includes: various media that can store program codes, such as ROM, RAM, magnetic or optical disks.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.