CN-121988532-A - Cross belt sorting system and method based on visual monitoring

CN121988532ACN 121988532 ACN121988532 ACN 121988532ACN-121988532-A

Abstract

The invention discloses a cross-belt sorting system and a method based on visual monitoring, which relate to the technical field of logistics sorting and comprise the following steps that a data acquisition and processing module acquires the operation data of cross-belt sorting equipment in a target area in real time and dynamically evaluates the operation state of the equipment; the visual monitoring module acquires the actual space layout of equipment, constructs a visual plan, combines the running state of the equipment, maps the actual space layout to the plan through color coding, constructs a dynamic updating map of the running state of the equipment, obtains key running indexes of the equipment by utilizing a sliding time window technology, sets a dynamic threshold value by an early warning and decision support module, automatically triggers a hierarchical early warning system, highlights abnormal equipment by the coupling map, generates a preliminary optimizing suggestion of the equipment, integrates the map, the key running indexes, early warning information and personnel performance multidimensional data by the operation cockpit module, constructs an integrated operation cockpit view, and completes a cross-band sorting scheme of visual monitoring. The invention saves the monitoring manpower.

Inventors

HUANG JIANFENG
ZHU YUJUN
YING CHUN
YAN TINGBIN
LI WEN
WANG TONG

Assignees

圆宇信息科技(上海)有限公司

Dates

Publication Date: 20260508
Application Date: 20251203

Claims (10)

1. A cross-belt sorting system based on visual monitoring, comprising: The system comprises a data acquisition and processing module, a visual monitoring module, a key operation index module, an early warning and decision support module and an operation cockpit module; the data acquisition and processing module is used for acquiring the operation data of the cross-belt sorting equipment of the target area in real time based on the sensor and dynamically evaluating the operation state of the cross-belt sorting equipment; the visual monitoring module is electrically connected with the data acquisition and processing module, acquires the actual spatial layout of the cross-belt sorting equipment, constructs a visual plan completely corresponding to the equipment, combines the running state of the cross-belt sorting equipment, maps the visual plan to the visual plan in real time through color coding, and constructs a dynamic update map of the running state of the cross-belt sorting equipment; The key operation index module is electrically connected with the visual monitoring module, dynamically updates the map based on the operation state of the cross-belt sorting equipment, and obtains key operation indexes of the cross-belt sorting equipment by utilizing a sliding time window technology; The early warning and decision support module is electrically connected with the key operation index module, a dynamic threshold is set based on the key operation index of the cross-belt sorting equipment, if the key operation index exceeds the dynamic threshold, the hierarchical early warning system is automatically triggered, the abnormal equipment is highlighted by coupling the dynamic updating map of the operation state of the cross-belt sorting equipment, and the equipment preliminary optimization suggestion is generated; The operation cockpit module is electrically connected with the early warning and decision support module, the key operation index module and the visual monitoring module, and is used for integrating dynamic updating patterns, key operation indexes, early warning information and personnel performance multidimensional data of the operation state of the cross-belt sorting equipment, constructing an integrated operation cockpit view and completing a cross-belt sorting scheme of visual monitoring.
2. The cross-belt sorting system based on visual monitoring of claim 1, wherein the data acquisition and processing module comprises: the photoelectric sensor unit is used for monitoring the passing rate of the package of the feeding platform and the arrival time of the package in real time based on the photoelectric sensor and calculating the arrival quantity of the package in unit time; The label unit is used for scanning each package RFID label based on the RFID reader, acquiring package identity information, and calculating the bar code recognition success rate and the package backlog quantity of each link; The sorting trolley movement state unit is used for acquiring the movement state of the sorting trolley in real time according to the sorting trolley vehicle-mounted PLC to obtain the specific position, speed and loading state of the sorting trolley; The deviation unit is used for reading the information of the sorting trolley and the package based on the two-dimensional code identifier, checking whether the position and the state of the sorting trolley are abnormal, and calculating the coordinate deviation with the map; The fault unit is used for monitoring the mechanical faults of the deviation, falling and clamping stagnation of the sorting trolley body based on the vibration sensor; The grid port state unit is used for monitoring the grid port state based on the weight sensor, judging that the grid port is fully loaded and blocked abnormally, judging that the grid port is fully loaded if the grid port weight continuously exceeds a set threshold value for 3 seconds, and judging that the grid port is blocked if the grid port weight is unchanged for a long time and has backlog on the upstream; The current abnormality unit is used for monitoring the motor current of the sorting machine in real time based on the current sensor, identifying current abnormality fluctuation, presuming the motor fault of the cross-belt sorting equipment, judging overload abnormality if the current continuously exceeds 120% of the rated value and reaches 5 seconds, and judging stalling if the current is lower than 10% of the rated value; The key characteristic index unit integrates real-time data of the workpiece feeding platform, the sorting trolley and the grid interface as real-time operation data of the cross-belt sorting equipment, performs data preprocessing, and extracts key characteristic indexes of the cross-belt sorting equipment; The cross belt sorting equipment comprises a piece feeding table, a sorting trolley and a grid; calculating the arrival quantity of the package in unit time, the bar code identification success rate and the package backlog quantity of each link; the mode unit defines a state machine for each equipment unit of the workpiece feeding platform, the sorting trolley and the grid, and the states can be divided into three modes of normal, abnormal and locking; the state judgment engine unit takes the real-time operation data and key characteristic indexes of the cross-belt sorting equipment as input, takes the current operation state of the cross-belt sorting equipment as output, and establishes a state judgment engine; And the evaluation unit is used for judging and dynamically evaluating the running state of the cross-belt sorting equipment in real time based on the state judgment engine.
3. The cross-belt sorting system based on visual monitoring of claim 1, wherein the visual monitoring module comprises: The space layout unit is used for acquiring the actual space layout of the cross-belt sorting equipment based on the field mapping data to obtain the accurate positions and numbers of the workpiece supply table, the sorting trolley and the grid openings; The plan view unit is used for creating a 1:1 ratio visual plan view, mapping the actual spatial layout of the cross-belt sorting equipment to the visual plan view, and obtaining rectangular-shaped icons of the workpiece supply platform, sorting trolley running tracks, grid icons and corresponding numbers; a rule definition unit that defines a color coding-state mapping rule; The system comprises a piece supply platform judging unit, a warning system and a warning system, wherein the piece supply platform judging unit is used for marking green if the number of the package backlog of each piece of the piece supply platform is smaller than a preset threshold A and normal; The sorting trolley judging unit is used for marking the sorting trolley as gray if the sorting trolley is not loaded with packages and judging that the sorting trolley is empty at the moment; if the sorting trolley scans packages and is going to the target grid, marking the packages as blue, and judging that the sorting trolley is carrying cargo at the moment; if the system does not receive the state update of the sorting trolley in a specific time window, the system is marked as yellow, and the communication of the sorting trolley at the moment is judged to be interrupted; The grid mouth judging unit is used for marking green if the arrival amount of the package in the unit time of the grid mouth is less than 80 percent and judging that the moment is normal, marking yellow if the arrival amount of the package in the unit time of the grid mouth is less than 95 percent and more than or equal to 80 percent and judging that the arrival amount of the package in the unit time of the grid mouth is close to a full bag, marking red if the arrival amount of the package in the unit time is more than or equal to 95 percent and judging that the grid mouth is in a full load or blocking abnormality at the moment.
4. A cross-belt sorting system based on visual monitoring as in claim 3, wherein the visual monitoring module further comprises: And the map dynamic updating unit is used for acquiring the running data of the cross-belt sorting equipment of the target area in real time, judging and dynamically evaluating the running state of the cross-belt sorting equipment in real time, mapping the cross-belt sorting equipment to the visual plan view in real time by combining with a color coding-state mapping rule, automatically updating the color and state information of each icon of the cross-belt sorting equipment, and constructing a dynamic updating map of the running state of the cross-belt sorting equipment.
5. The cross-belt sorting system based on visual monitoring of claim 4, wherein the key operation index module comprises: the data processing unit is used for setting 1 minute as a fixed statistical time window, collecting the piece supply time, the drop time, the sorting trolley number and the grid number data in the statistical time window in real time through the Internet of things sensor, and cleaning the data; The actual processing time unit is used for calculating the time difference between the package supply and the grid falling for each piece of effective data to obtain the actual processing time of each package; the dynamic correction unit is used for dynamically correcting the statistical time window to which the data belongs by combining the actual processing time of each package based on the data transmission delay problem; the sorting trolley number calculating unit is used for calculating the number of sorting trolleys passing through the piece supply area in the statistical time window; the detour period calculation unit is used for calculating the average time required by the time of the detour of the sorting trolley for one circle on the basis of the running track and the speed of the sorting trolley, and taking the average time as the detour period; The reflow judging unit is used for judging that one reflow occurs if the actual processing time of a certain package is longer than the detour period, and judging that one reflow occurs if the actual processing time of a certain package is shorter than or equal to the detour period but the grid number does not belong to the target grid section associated with the piece supply area; The ticket reflow unit is used for observing the supplied ticket in the statistical time window, and marking the ticket reflow unit as the ticket reflow if the package of the falling message is not received in the continuous monitoring; the total reflux quantity unit is used for collecting all times judged to be reflux in the statistical time window to obtain the total reflux quantity of the package of the part supply area; and the parcel reflux rate calculation unit is used for calculating the parcel reflux rate of the delivery area based on the number of the sorting trolleys passing through the delivery area in the statistical time window and the total parcel reflux rate of the delivery area.
6. The cross-belt sorting system based on visual monitoring of claim 5, wherein the critical operation index module further comprises: The quantity calculating unit is used for calculating the quantity of all sorting trolleys passing through the piece supply area in the statistical time window; The total number of supplied pieces obtaining unit is used for calculating the total number of supplied pieces in the statistical time window based on the obtained actual processing time of each package; The empty number calculation unit is used for obtaining the total number of sorting trolleys in the target area and combining the total quantity of returned packages and the total quantity of supplied packages in the part supply area in the statistical time window to obtain the empty number of the sorting trolleys; the empty rate calculation unit is used for obtaining the empty rate of the sorting trolley based on the number of the sorting trolleys passing through the feeding area and the empty number of the sorting trolleys in the statistical time window; and the key operation index unit integrates the parcel reflux rate and the empty rate of the delivery area to obtain key operation indexes of the cross-belt sorting equipment.
7. The cross-belt sorting system based on visual monitoring of claim 6, wherein the early warning and decision support module comprises: The data collection unit is used for collecting data of the same time period and the same type of date in the past 4-8 weeks of each index based on the key operation index of the cross-belt sorting equipment; and a stationary fluctuation index datum line calculating unit for obtaining the operation data of the cross-belt sorting equipment in a 15-minute time window, combining the same time period and the same type of date data of each index in the past 4-8 weeks, and calculating the weighted average value of the data in the past 1 hour and the same period and the same type of history by using a moving average method to serve as a stationary fluctuation index datum line.
8. The cross-belt sorting system based on visual monitoring of claim 7, wherein the early warning and decision support module further comprises: a range setting unit that sets a dynamic threshold range based on the stationary fluctuation index reference line; the dynamic threshold range is automatically adjusted according to the fluctuation standard deviation of the date data of the same type in the same time period of the history; The system comprises a grading early warning mechanism unit, a warning signal triggering unit, a red early warning unit, a warning unit and a maintenance unit, wherein the grading early warning mechanism unit is designed to trigger the grading early warning mechanism, the yellow early warning unit is marked when a key operation index exceeds 85% of a dynamic threshold range and needs to be concerned continuously, the orange early warning unit is marked when the key operation index exceeds 100% of the dynamic threshold range, the warning signal is triggered, abnormal equipment is highlighted on a dynamic updating map of the operation state of the cross-band sorting equipment, the red early warning unit is marked when the key operation index exceeds 120% of the dynamic threshold range and lasts for more than 5 minutes, and the emergency early warning unit is immediately triggered to inform relevant maintenance personnel; The root cause unit is used for dynamically updating the map according to the operation state of the cross-belt sorting equipment, analyzing key operation indexes for triggering early warning by utilizing a root cause analysis algorithm in combination with real-time operation data and historical operation data of the cross-belt sorting equipment, and positioning the equipment for triggering early warning root cause; The reflux rate abnormality unit is used for automatically highlighting the reflux grid and 1-2 piece supply tables with highest recent recognition error rate according to the abnormal rise condition of the reflux rate, and deducing whether the reflux grid is full or blocked, the bar code is fuzzy or damaged, and the piece supply table scans the camera fault or the dirt reason; The empty rate abnormality unit is used for automatically highlighting all the delivery tables according to the condition of abnormal rising of the empty rate and deducing whether the efficiency of the delivery personnel is low or not and whether the package supply is interrupted or the delivery tables are blocked; And the preliminary optimization unit is used for generating equipment preliminary optimization suggestions based on root cause analysis results.
9. The cross-belt sorting system based on visual monitoring of claim 8, wherein the operator cabin module interior comprises in particular: An integrated operation cockpit view unit, wherein the integrated operation cockpit view is constructed by taking a dynamic update map of the operation state of the cross-belt sorting equipment as a central area, key operation indexes as KPI index cards, early warning information as an early warning information panel and personnel performance data as an auxiliary analysis plate; The visual monitoring unit is used for dynamically updating a map based on an integrated operation cockpit view, mapping operation data and operation states of the cross-belt sorting equipment in a central area in real time, providing global monitoring, enabling a KPI (key performance indicator) indicator card to build visual icons to display key operation indicators, quantifying the core operation efficiency of the display equipment, enabling an early warning information panel to prompt with different early warning information, rapidly positioning abnormal equipment, timely taking corresponding measures, assisting in analyzing personnel performance data of a plate, recording personnel working efficiency and operation accuracy, and realizing visual monitoring and intelligent management of the cross-belt sorting scheme.
10. A method of cross-belt sorting based on visual monitoring for performing a cross-belt sorting system based on visual monitoring as claimed in any one of claims 1 to 9, comprising: S1, acquiring operation data of the cross belt sorting equipment of a target area in real time based on a sensor, and dynamically evaluating the operation state of the cross belt sorting equipment; S2, acquiring the actual space layout of the cross-belt sorting equipment, constructing a visual plan corresponding to the equipment completely, combining the running state of the cross-belt sorting equipment, mapping to the visual plan in real time through color coding, and constructing a dynamic updating map of the running state of the cross-belt sorting equipment; s3, dynamically updating the map based on the running state of the cross-belt sorting equipment, and obtaining key operation indexes of the cross-belt sorting equipment by utilizing a sliding time window technology; S4, setting a dynamic threshold based on the obtained key operation index of the cross-belt sorting equipment, automatically triggering a grading early warning system if the key operation index exceeds the dynamic threshold, coupling the operation state dynamic updating map of the cross-belt sorting equipment to highlight abnormal equipment, and generating an equipment preliminary optimization suggestion; S5, dynamically updating the map, key operation indexes, early warning information and personnel performance multidimensional data of the operation state of the integrated cross-belt sorting equipment, constructing an integrated operation cockpit view, and completing a cross-belt sorting scheme of visual monitoring.

Description

Cross belt sorting system and method based on visual monitoring Technical Field The invention relates to the technical field of logistics sorting, in particular to a cross belt sorting system and method based on visual monitoring. Background In an express logistics sorting center, cross-belt sorting equipment is used as a core sorting tool, the operation efficiency of the cross-belt sorting equipment directly influences the overall logistics throughput capacity, the current cross-belt equipment management has the outstanding problems that equipment is large in scale and difficult to associate with azimuth, new online equipment or new job-entering management staff are difficult to quickly correspond a system interface with the actual azimuth on site, management efficiency is low, the existing system displays equipment abnormality in a report form, visual association with a physical position is lacking, the management staff is difficult to quickly locate, abnormality discovery relies on manpower, the equipment operation abnormality needs to depend on the field observation or monitoring video of the management staff, response is lag, efficiency loss is easy to cause, data dispersion and analysis are difficult, operation data are dispersed in a plurality of menus or systems, unified view is lacking, analysis difficulty is high, key information is easy to miss, and decision-making efficiency is influenced. Disclosure of Invention In order to solve the technical problems, the cross belt sorting system and the method based on visual monitoring are provided. In order to achieve the above purpose, the invention adopts the following technical scheme: a cross-belt sorting system based on visual monitoring, comprising: The system comprises a data acquisition and processing module, a visual monitoring module, a key operation index module, an early warning and decision support module and an operation cockpit module; the data acquisition and processing module is used for acquiring the operation data of the cross-belt sorting equipment of the target area in real time based on the sensor and dynamically evaluating the operation state of the cross-belt sorting equipment; the visual monitoring module is electrically connected with the data acquisition and processing module, acquires the actual spatial layout of the cross-belt sorting equipment, constructs a visual plan completely corresponding to the equipment, combines the running state of the cross-belt sorting equipment, maps the visual plan to the visual plan in real time through color coding, and constructs a dynamic update map of the running state of the cross-belt sorting equipment; The key operation index module is electrically connected with the visual monitoring module, dynamically updates the map based on the operation state of the cross-belt sorting equipment, and obtains key operation indexes of the cross-belt sorting equipment by utilizing a sliding time window technology; The early warning and decision support module is electrically connected with the key operation index module, a dynamic threshold is set based on the key operation index of the cross-belt sorting equipment, if the key operation index exceeds the dynamic threshold, the hierarchical early warning system is automatically triggered, the abnormal equipment is highlighted by coupling the dynamic updating map of the operation state of the cross-belt sorting equipment, and the equipment preliminary optimization suggestion is generated; The operation cockpit module is electrically connected with the early warning and decision support module, the key operation index module and the visual monitoring module, and is used for integrating dynamic updating patterns, key operation indexes, early warning information and personnel performance multidimensional data of the operation state of the cross-belt sorting equipment, constructing an integrated operation cockpit view and completing a cross-belt sorting scheme of visual monitoring. Preferably, the data acquisition and processing module specifically includes: the photoelectric sensor unit is used for monitoring the passing rate of the package of the feeding platform and the arrival time of the package in real time based on the photoelectric sensor and calculating the arrival quantity of the package in unit time; The label unit is used for scanning each package RFID label based on the RFID reader, acquiring package identity information, and calculating the bar code recognition success rate and the package backlog quantity of each link; The sorting trolley movement state unit is used for acquiring the movement state of the sorting trolley in real time according to the sorting trolley vehicle-mounted PLC to obtain the specific position, speed and loading state of the sorting trolley; The deviation unit is used for reading the information of the sorting trolley and the package based on the two-dimensional code identifier, checking whether the position and the stat