CN102390578A - Realizing method for quantitative grain counting and device thereof - Google Patents

Realizing method for quantitative grain counting and device thereof Download PDF

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Publication number
CN102390578A
CN102390578A CN201110214864XA CN201110214864A CN102390578A CN 102390578 A CN102390578 A CN 102390578A CN 201110214864X A CN201110214864X A CN 201110214864XA CN 201110214864 A CN201110214864 A CN 201110214864A CN 102390578 A CN102390578 A CN 102390578A
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conveyer
memory bucket
grain number
memory
control system
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CN201110214864XA
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CN102390578B (en
Inventor
徐菊瑛
王红
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SHANGHAI CHAOYANG ELECTRICAL AND MECHANICAL EQUIPMENT CO Ltd
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SHANGHAI CHAOYANG ELECTRICAL AND MECHANICAL EQUIPMENT CO Ltd
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Priority to CN201110214864.XA priority Critical patent/CN102390578B/en
Priority to PCT/CN2011/078523 priority patent/WO2013016881A1/en
Publication of CN102390578A publication Critical patent/CN102390578A/en
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Publication of CN102390578B publication Critical patent/CN102390578B/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65BMACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B57/00Automatic control, checking, warning, or safety devices
    • B65B57/20Applications of counting devices for controlling the feed of articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65BMACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B1/00Packaging fluent solid material, e.g. powders, granular or loose fibrous material, loose masses of small articles, in individual containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, or jars
    • B65B1/30Devices or methods for controlling or determining the quantity or quality or the material fed or filled
    • GPHYSICS
    • G06COMPUTING; CALCULATING OR COUNTING
    • G06MCOUNTING MECHANISMS; COUNTING OF OBJECTS NOT OTHERWISE PROVIDED FOR
    • G06M1/00Design features of general application
    • G06M1/08Design features of general application for actuating the drive
    • G06M1/10Design features of general application for actuating the drive by electric or magnetic means
    • G06M1/101Design features of general application for actuating the drive by electric or magnetic means by electro-optical means

Abstract

The invention discloses a realizing method for quantitative grain counting and device thereof, comprising a control system, a feeder, a conveyor, a camera, a memory hopper and a retainer, wherein said control system comprises an image processor, a combined calculation processor and PLC (programmable logic controller); said feeder feeds material to the conveyor in scattered way; at least one layer of memory hopper is set below the conveyor; the camera and the image processor performs image data collection and analysis and grain calculation on material on the conveyor, and delivers the material to the corresponding memory hopper, wherein the material grain number is corresponding to the memory hopper; the combined calculation processor performs combined calculation on the material amount in the memory hopper and compares it with the preset target grain number, and selects the memory combination with a grain number which is closest to the target grain number within allowed deviation range, and discharges the material in the memory hopper. The invention combines the batch CCD grain counting technology with uncontrollable grain number with combined calculation technology to largely raise the precision and speed on quantitative grain calculation.

Description

Quantitative several implementation method and device
Technical field
The present invention relates to a kind of counting grain machine, specifically belong to quantitative several methods and device that an a kind of CCD number technology and combination technique combine.
Background technology
Counting grain machine is a kind of counting assembly; Usually to granular articles such as food, medicine, seed, electronic devices and components, plastic parts, metal partss; Packing demand number according to setting the grain number goes out corresponding packed article, and this equipment is widely used in every field such as production, commerce.For realizing with the amounts of particles being that the quantitative package (like 100 pills, 1000 seeds etc.) of unit can be taked several methods, volumetry, weight method.
Several methods are the most direct method, and are the most accurate, but speed is the slowest, investment is maximum.
Several traditional equipment adopt the infrared ray sensing mode; This is a kind of consecutive numbers grain method; When material passed through the infrared ray curtain, infradred sensor can send the ON/OFF signal, and an ON/OFF signal is just represented a material; Through the ON/OFF signal is counted, when reaching setting quantity, can stop feed immediately.The advantage of this equipment is that quantitative several precision is higher; It is slow that but weak point is speed; And a material can only be arranged at every turn through the infrared ray curtain, even otherwise two above materials are arranged simultaneously through also only sending an ON/OFF signal, cause last count results inaccurate; Especially under single Material Cost condition with higher, can cause manufacturer's greater loss.
In recent years, along with the development of the technological universal and corresponding components and parts of CCD (Charge Coupled Device, charge-coupled device), the counting grain machine that technological development is come out by CCD is also progressively applied on market.CCD is a kind of semiconductor devices, can be converted into digital electric signal to optical image, and the CCD device is divided into two types of line array CCD and area array CCDs by the arrangement mode of its photosensitive unit.Wherein, line array CCD adopts the mode of scanning imagery, and area array CCD adopts the mode of shooting, obtains the image of material respectively, through image recognition software material is carried out several then.Linear CCD technology also is a kind of consecutive numbers grain method, can count the material on a plurality of passages simultaneously, and when near setting quantity, most of passages that stop only stay a passage feed, reaches to stop feed when setting quantity.With the infrared pickoff compared with techniques, the cost of this equipment is higher, precision is lower slightly, and speed improves a lot, but still is much slower than weight method.And area array CCD technique is an a kind of batch of number method, can make a video recording to the material that gets into image pickup scope, through image recognition technology the material in the imaging scope is counted again.This equipment can obtain the grain number of each batch apace, but because the grain number of each batch is uncontrollable, so the grain number that can't obtain setting.
Volumetry is a kind of method of substitution, and speed is fast, reduced investment, but least accurate.
Weight method also is a kind of method of substitution, if single weight of material has good uniformity, when using it for quantitative several, can access higher quantitative accuracy and discharge velocity faster, and equipment price is cheap.But the single weight homogeneity of many materials differs greatly in the practical operation, such as corn seed is because different its single weight of moisture what, grain size difference, shape possibly differ one times, plastic parts because moisture content change, shape error, different its single weight of material density also possibly differ 20%.When such material used weighing technology number, precision will reduce greatly.
Summary of the invention
The technical matters that the present invention will solve provides a kind of quantitative several implementation method and device, can carry out high speed quantitative counting accurately to the identical or different material of single weight.
For solving the problems of the technologies described above, quantitative several implementation method of the present invention is carried out several to the material on the conveyer that transmits material, and with in mass transport to the corresponding memory bucket, and material grain number is corresponding with the memory bucket; The memory bucket of known grain number and the material quantity of conveyer are carried out combination calculation; Perhaps the material quantity of the memory bucket of known grain number is carried out combination calculation; Compare with expected objective grain number; Select in the allowance deviation scope and near the combination of target grain number, and the memory bucket that will choose and/or the material in the conveyer are discharged.
The present invention also provides a kind of quantitative several devices, comprises control system, feeder, conveyer, camera, memory bucket and loading head, and wherein feeder, conveyer, camera and memory bucket all are electrically connected with control system; Said control system comprises image processor, combination calculation treater and PLC; Said conveyer is more than two; Adopt step wise or oscillatory type to drive; Feeder is positioned at the top of conveyer, and the below of conveyer is provided with one deck memory bucket at least by layer, and the discharge end of every conveyer is relative with a top layer memory bucket inlet point that is positioned at its below respectively; Each memory bucket of top layer and interlayer is respectively equipped with two side discharging openings; A side discharging opening is relative with the inlet point of following one deck memory bucket, and the inlet point of another side discharging opening and loading head is relative, and the memory bucket of bottom is provided with and the corresponding discharging opening of loading head inlet point.
In said structure, said camera is area array CCD camera or line array CCD camera, be responsible for to gather the graphicinformation of each batch material on the conveyer, and graphicinformation is sent to image processor draws corresponding batch material grain number.Perhaps, said camera is face battle array CMOS camera or linear array CMOS camera, be responsible for to gather the graphicinformation of each batch material on the conveyer, and graphicinformation is sent to image processor draws corresponding batch material grain number.
Further; Said conveyer moves to each batch material of known grain number respectively in the corresponding top layer memory bucket; By top layer memory bucket material is successively moved to lower floor's memory bucket again; The grain number information of each batch material is along with the mobile route transmission of material, and corresponding with the memory bucket of last storage material.
Further, said feeder is the vibra feeder that links to each other with feed bin, and vibra feeder is provided with inlet, and is electrically connected with control system, and the switching of the amplitude of said vibra feeder, oscillation frequency, inlet is controlled by control system.
Further, said conveyer also comprises makes the material individual layer be laid on the height adjustment baffle plate on the conveyer, and by the intermittently mobile step drive device of control system controlling and driving conveyer, said height adjustment baffle plate is positioned at the top of conveyer.
Further, said conveyer comprises that also the vibration of control conveyer makes the material individual layer be laid on the vibrator on the conveyer.
Further, said conveyer is moved ahead by the step wise driving device controls that is electrically connected with control system.
The present invention adopts a batch number mode, goes out the material grain number on the conveyer with linear array or area array CCD camera combining image treater number, is temporary in the memory bucket, passes through combination calculation then, selects suitable memory bucket, obtains the number near setting value; The form that adopts CCD number and memory bucket combination calculation to combine, quantitative several precision and the speed of discharge obviously are superior to having now several equipment.
Description of drawings
Below in conjunction with the accompanying drawing and the specific embodiment the present invention is done further detailed explanation:
Fig. 1 is a perspective view of the present invention;
Fig. 2 is a device scheme drawing of the present invention;
Fig. 3 is a control system composition diagram of the present invention.
Wherein description of reference numerals is following:
1 is feed bin; 2 is feeder; 3 is conveyer; 4 is camera; 5 are the memory bucket; 6 is loading head; 7 is image processor; 8 is the combination calculation treater; 9 is PLC.
The specific embodiment
Quantitative several devices of the present invention comprise control system, feeder 2, conveyer 3, camera 4, memory bucket 5 and loading head 6, and wherein feeder 2, conveyer 3, camera 4 and memory bucket 5 all are electrically connected with control system; Said control system comprises image processor 7, combination calculation treater 8 and PLC9, like Fig. 2, shown in 3.Said conveyer 3 is more than two; Adopt step wise or oscillatory type to drive; Feeder 2 is positioned at the top of conveyer 3, and the below of conveyer 3 is provided with one deck memory bucket 5 at least by layer, and the discharge end of every conveyer 3 is relative with top layer memory bucket 5 inlet points that are positioned at its below respectively; Each memory bucket 5 of top layer and interlayer is respectively equipped with two side discharging openings; A side discharging opening is relative with the inlet point of following one deck memory bucket 5, and the inlet point of another side discharging opening and loading head 6 is relative, and the memory bucket 5 of bottom is provided with and the corresponding discharging opening of loading head 6 inlet points.
Said feeder 2 connects feed bin 1, is used for disperseing feed to conveyer 3.After conveyer 3 was discharged material, the control system output command made feeder 2 to conveyer 3 feeds.Feeder 2 is generally the vibra feeder that links to each other with feed bin 1, and vibra feeder is provided with inlet, and is electrically connected with control system, and the switching of the amplitude of said vibra feeder, oscillation frequency, inlet is controlled by control system.Also can use belt-type or other modes such as Vibration Storage bin, spiral according to material characteristic.
Said conveyer 3 is provided with 4 to 40 as required, and every conveyer 3 all has corresponding numbers in control system.
When using area array CCD shooting mode, conveyer 3 can be arranged in circle, linear or polygon.The distance that conveyer 3 can be advanced forward at every turn and set, its actuating device can be stepping motor, servomotor, alternating current dynamo, DC machine, cylinder or hydraulic actuating cylinder.Overlapping in order to prevent material, influence several precision, conveyer 3 tops are provided with the height adjustment baffle plate, make overlapping material to pass through.Conveyer 3 also is equipped with oscillatory system, prevents that through vibration material is overlapping.
When using line array CCD shooting mode, conveyer 3 has vibrator.Conveyer 3 can be arranged in circle, linear.When conveyer 3 adopted vibrator to drive, its Oscillation Amplitude, vibration intensity, time of vibration can be set by control system.
Said camera 4 is made up of camera lens, CCD photoelectric commutator and fuselage, and it is responsible for absorbing the material image on the conveyer 3, and is sent to image processor 7.For obtaining photographic effect clearly, dispose appropriate illumination, be installed in the correct position of equipment.
The below of conveyer 3 is provided with one deck memory bucket 5 at least by layer; The discharge end of every conveyer 3 is relative with a top layer memory bucket inlet point that is positioned at its below respectively; Top layer memory bucket is accepted the material that conveyer is discharged; After receiving the discharge instruction of control system, the material in the bucket is expelled to down one deck memory bucket 5 or loading head 6.Memory bucket 5 hierarchal arrangement are generally 1~5 layer, and material is entered by conveyer 3 or upper strata memory bucket, is expelled to down one deck memory bucket or loading head 6.Through selected memory bucket 5 direct discharge to the loading heads 6 of combination calculation, after lower floor's memory bucket was drained, upper strata memory bucket or conveyer discharge replenished, and so move in circles.Each memory bucket of top layer and interlayer is respectively equipped with two side discharging openings; A side discharging opening is relative with the inlet point of following one deck memory bucket; The inlet point of another side discharging opening and loading head is relative, and the memory bucket of bottom is provided with and the corresponding discharging opening of loading head inlet point.Memory bucket discharging opening door can have spring, also can not have spring.The discharging opening door can adopt cylinder, stepper motor, servo motor driven.
Loading head 6 can be that hopper also can be set belt or other material-gathering devices, and the material by conveyer 3 is discharged enters in follow-up wrapping machine or other equipment through loading head 6.
Image processor 7 is made up of image processing circuit and image identification unit.Image processing circuit is divided into analogue signal processor, AD converter, digital signal processor.Be sent to image identification unit through the image processing circuit image data processed, image identification unit is handled the grain number that draws each batch material on the conveyer, is sent to combination calculation treater 8.Image identification unit has material characteristic memory function, dynamic compensation function, noise filtering function and other necessary function.
Combination calculation treater 8 comprises memory device and combination calculation unit.The grain logarithmic data of each conveyer 3 of memory storage and memory bucket 5.Material grain number on the conveyer 3 that is transmitted by image identification unit is stored in the cooresponding memory device.When material drained into lower floor's memory bucket 5, the grain logarithmic data of memory storage also correspondingly was transferred to down the corresponding memory bucket 5 of one deck, by that analogy.The combination calculation unit carries out combination calculation to each memory bucket 5 of known grain number with conveyer 3, at C n 1+ C n 2+ C n 3++ C n nIn kind of the combined result, with the target grain number of setting relatively, select near setting value and meet the combination of deviation standard.
PLC9 is the core component of control system, and the action of control feeder 2, camera 4, conveyer 3, memory bucket 5, loading head 6 makes the total system interlock.
Quantitative several implementation method comprises: the material on the conveyer 3 that transmits material carries out several, and with in mass transport to the corresponding memory bucket 5, and material grain number is corresponding with memory bucket 5; The memory bucket 5 of known grain number and the material quantity of conveyer 3 are carried out combination calculation; Perhaps the memory bucket 5 to known grain number carries out combination calculation; Compare with expected objective grain number; Select in the allowance deviation scope and near the combination of target grain number, and the memory bucket 5 that will choose and/or the material in the conveyer 3 are discharged.
When using the area array CCD mode to carry out several, the material that remains static on the conveyer 3 is made a video recording, go out the material grain number under this state through image recognition technology moment number, material to memory bucket 5 is discharged in instruction according to control system then.In order to improve several precision, can carry out the several shooting, utilize known math modeling filtration, average then.After material was discharged, conveyer 3 was advanced forward according to the instruction of control system and is stopped after the distance of setting.At this moment, feeder 2 is to conveyer 3 feed, gets into next shooting, image recognition, several process.Also can be to bottom memory bucket several discharge, accumulative total grain.
When using the line array CCD mode to carry out several; Material on the conveyer 3 enters the memory bucket by instruction; When material is in the falling bodies process, make a video recording continuously, go out the material grain number under this state, stop through one section setting-up time or after reaching setting grain number with the image recognition technology number.When memory bucket 5 after material is discharged in instruction according to control system, the material on the conveyer 3 enters memory bucket 5 by instruction once more, gets into next shooting, image recognition, several step.
In the present embodiment, as shown in Figure 1, the feeder 2 on top is a vibra feeder, is provided with 6 conveyers 3, and every conveyer 3 has two-layer memory bucket 5 up and down, and every layer is provided with 6 memory buckets 5, has 12 memory buckets 5.6 conveyers 3 are arranged in a linear, and use two table top battle array ccd video cameras 4, every pick up camera 4 corresponding 3 conveyers 3.Every conveyer 3 all has corresponding numbering with each memory bucket 5 in control system.
When not having material on the conveyer 3, vibra feeder is received the instruction of control system, opens inlet, and simultaneously conveyer 3 is according to the setting certain distance that moves ahead, and vibra feeder disperses feeds to conveyer 3.Pick up camera 4 is installed in the correct position of conveyer 3 tops, and disposes appropriate illumination, and the material that remains static on the conveyer 3 is at least once made a video recording, and simultaneously the view data that obtains is sent to image processor 7.7 pairs of view data of image processor are handled, and analyze the material grain number on each conveyer 3.If upper strata memory bucket 5 be empty, control system is sent instruction to step drive device, and the conveyer 3 one section setpoint distance that continues to move ahead makes the material on the conveyer 3 enter bottom memory bucket 5, and the grain number of material is stored to this memory and struggles against in 5 cooresponding memory devices simultaneously.If lower floor's memory bucket 5 is empty; Control system is sent the discharge instruction to upper strata memory bucket 5; Upper strata memory bucket 5 is opened and the corresponding side discharging opening of lower floor's memory bucket 5 inlet points; Material in the memory bucket 5 is drained into lower floor's memory bucket 5, at this moment, be stored in material grain number in the upper strata memory bucket 5 pairing memory devices and shift and be stored in lower floor's memory bucket 5 corresponding memory devices.Be preset with target grain number and allowance deviation in the combination calculation treater 8; After reading the material grain number of each memory bucket 5 in the memory device; According to the permutation and combination principle number being carried out in all combinations calculates; Compare simultaneously, select in the allowance deviation scope and make up near the memory bucket 5 of target grain number with target grain number and allowance deviation.Control system is opened the discharging opening of selected memory bucket 5 according to the memory bucket combined information that combination calculation treater 8 obtains, and wherein material is drained in the loading head 6.
Whole feed, several, combination calculation, discharge process back and forth carry out under the control of control system.
In addition, conveyer can be discharge once to upper strata memory bucket, upper strata memory bucket to the discharge action of lower floor's memory bucket, also can be the several discharge.Gather the view data of material if use linear array CCD camera; Conveyer is received instruction discharge in the memory bucket of control system; Linear array CCD camera is made a video recording continuously when material is in the falling bodies process; Image data transmission to the image identification unit that obtains is analyzed the grain number, and is stored in the memory device of corresponding memory bucket.Above-mentioned ccd video camera also can substitute with cmos camera.
In the above-described embodiments; Have 12 memory buckets; According to the permutation and combination principle, a kind grain array is closed to have
Figure BDA0000079664450000101
at most.Can adjust the grain number of each batch blanking through the miles of relative movement of amplitude, frequency and conveyer of control and regulation vibra feeder, thereby improve the success ratio of combination.
In the legacy equipment, the precision of simple weighing-appliance is 2%, speed is 320000/minute; The precision of a simple line array CCD number equipment is 0.1%, its speed of 1 be about 1000/inferior, 5 times/minute, promptly 5000/minute,, then be 30000/minute if use 6.And quantitative several devices of the present invention; Precision is much higher than weight method and volumetry, and the precision of batch number is 0.1%, and it is in the majority that 3~5 memory buckets are chosen in combination usually; Therefore quantitative several the precision in final combination back are 0.3%~0.5%; And the speed of discharge is much higher than existing several methods, and discharge velocity can reach 30~60 times/minute, and several can reach 240000~480000/minute.
More than through specific embodiment the present invention has been carried out detailed explanation, this embodiment only is preferred embodiment of the present invention, it is not to limit the invention.Under the situation that does not break away from the principle of the invention; Equivalent replacement and improvement that those skilled in the art makes the number of plies, number and layout type, the marker method etc. of the quantity of conveyer and mounting means, memory bucket are in the technological category that all should be regarded as protecting in the present invention.

Claims (10)

1. quantitative several implementation method is characterized in that:
Material on the conveyer that transmits material carries out several, and with in mass transport to the corresponding memory bucket, and material grain number is corresponding with the memory bucket;
The memory bucket of known grain number and the material quantity of conveyer are carried out combination calculation; Perhaps the material quantity of the memory bucket of known grain number is carried out combination calculation; Compare with expected objective grain number; Select in the allowance deviation scope and near the combination of target grain number, and the memory bucket that will choose and/or the material in the conveyer are discharged.
2. quantitative several devices, it is characterized in that: comprise control system, feeder, conveyer, camera, memory bucket and loading head, wherein feeder, conveyer, camera and memory bucket all are electrically connected with control system; Said control system comprises image processor, combination calculation treater and PLC; Said conveyer is more than two; Adopt step wise or oscillatory type to drive; Feeder is positioned at the top of conveyer, and the below of conveyer is provided with one deck memory bucket at least by layer, and the discharge end of every conveyer is relative with a top layer memory bucket inlet point that is positioned at its below respectively; Each memory bucket of top layer and interlayer is respectively equipped with two side discharging openings; A side discharging opening is relative with the inlet point of following one deck memory bucket, and the inlet point of another side discharging opening and loading head is relative, and the memory bucket of bottom is provided with and the corresponding discharging opening of loading head inlet point.
3. quantitative several devices according to claim 2; It is characterized in that: said camera is area array CCD camera or line array CCD camera; Be responsible for to gather the graphicinformation of each batch material on the conveyer, and graphicinformation is sent to image processor draws corresponding batch material grain number.
4. quantitative several devices according to claim 2; It is characterized in that: said camera is face battle array CMOS camera or linear array CMOS camera; Be responsible for to gather the graphicinformation of each batch material on the conveyer, and graphicinformation is sent to image processor draws corresponding batch material grain number.
5. quantitative several devices according to claim 2; It is characterized in that: said conveyer moves to each batch material of known grain number respectively in the corresponding top layer memory bucket; By top layer memory bucket material is successively moved to lower floor's memory bucket again; The grain number information of each batch material is along with the mobile route transmission of material, and corresponding with the memory bucket of last storage material.
6. quantitative several devices according to claim 2; It is characterized in that: the vibra feeder of said feeder for linking to each other with feed bin; Vibra feeder is provided with inlet; And be electrically connected with control system, the switching of the amplitude of said vibra feeder, oscillation frequency, inlet is controlled by control system.
7. quantitative several devices according to claim 2; It is characterized in that: said conveyer also comprises makes the material individual layer be laid on the height adjustment baffle plate on the conveyer; And by the intermittently mobile step drive device of control system controlling and driving conveyer, said height adjustment baffle plate is positioned at the top of conveyer.
8. according to quantitative several the devices shown in the claim 2, it is characterized in that: said conveyer comprises that also the vibration of control conveyer makes the material individual layer be laid on the vibrator on the conveyer.
9. quantitative several devices according to claim 2 is characterized in that: said conveyer is moved ahead by the step wise driving device controls that is electrically connected with control system.
10. quantitative several devices according to claim 2 is characterized in that: the discharging opening of said memory bucket is provided with the discharging opening door by cylinder or stepper motor or servo motor driven.
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